The McDonalds Project.. by n0ftInc

26 minute(s) of a 56 minute read

The McDonalds Project..

Compliments of n0ftInc @ michiganvw.org

09.04.09

Not Red and Yellow, but hopefully she will do..some of you know of my recently acquired '59 Single Cab:



She is a runner, but needs some attention. I plan on having some of the issues resolved by Buses (September 19th), so I better get crackin'!

Issue: Leaky Front Wheel Cylineder & Master Cylinder
Fix: Convert to Disk Brakes

Donor Spindles..

Picked up some parts off a 944..

..hybrid 944/Bus 5" Welded Drop Spindles currently in progress by the guys over at WagensWest.

The 944 brakes will be able to be bolted on for awesome leak-free stopping power. Also converting to a Dual Circuit Master Cylinder as found on the Bay Window Buses.

Issue: Ride Height
Fix: New Lowered Suspension Goodies

Teaming up the Front Spindles with a 5" Narrowed Adjustable Beam, also being done by the guys at WagensWest. The beam is good for an addition 6" of drop if needed..at the cost of suspension.

The rear is going to get converted to IRS using a Beetle Transmission, Trailing Arms, Axels, and a couple items also fabricated by WagensWest.

Issue: Tires Too Tall & Wheels Wrong Pattern
Fix: New Tires On Porsche Wheels

Been searching all over for some neat Porsche wheels to run, but selections are pretty scarce in the 15" world. Ended up finding some old steelies in the 5x130 pattern. These are the same that the 911/944 used at spares. Calling around, I got ahold of these..three steelies and one spare. The price was right, and with a little bit of paint, should be alright for now.

Teaming the fronts up with a pair of 165/45s, I should be able to get as low as I am required to be by split window law. Rears will end up getting some 195/50s to maintain some economy, but not look super huge..plus, I already have some to put on.

Issue: Leaky Rear Main
Fix: New Clutch Kit & Seals

Had a little bit of free time, so I made a super detailed writeup for pulling this engine..

Step One: Remove Previous Owner's Custom Engine Diaper

Step Two: Remove Engine

Clutch:

Rear Main:

Some of the Wiring needs attention too:

 

14 days left!

09.05.09

As part of the purchase, the previous owner threw in this convertable - I needed it's transmission for my build. Here are a couple pics of that ordeal and one for inspiration.









 



09.06.09

Not much of an update, but degreased the Beetle Transmission and 1600DP. 





Also removed the heater boxes in prep to get some J-Pipes and cleaned out the doghouse..looks like something was living in there at one point..eww.



Hopefully tomorrow I will be pulling the rest of the old crap off the Bus..

09.09.09

I cut up and tossed the rest of the Beetle crap I didn't need, so that's gone..yay!

Clutch kit came today.

Drop Spindles & Beam to be done and shipped out by Friday..should be here early/mid next week.

Seal Kit, Mounts, Rear Disk Kit, and J-Pipes will be here Monday.

Haven't gotten any tracking for the tires.

09.12.09

Made a little bit of progress tonight..

Scored some SS lines off the same Porsche guy we got Darren's Bucket from..free!

Also took off some more useless crap..wires that went to nowhere, and some huge ass horn..haha.

Springplates off, and ready to be swapped out for some Adjustable IRS ones..

Also found some even thinner wheels for the fronts..just got to see if they'll clear the brakes.

Running out of things to remove..hmm.

C'mon UPS!

7 Days left. 

09.14.09

Got some more essentials today..

J Pipes:

Rear disk kit:

Seals:

Just talked to Nate at WagensWest today..crap still hasn't shipped.  I guess they're down a guy in their two man operation, so things aren't working out as planned. Shipping out "soon" though, and should be here USPS maybe Thursday, for sure on Friday..sonofabich. 

09.17.09

Some more paint, and played a little game of just the tip..

Thank you UPS..just in time. (165/45/15)

 



09.18.09

5" 944/Bus Drop Spindle..

5" Narrowed Adjustable Beam..

..tomorrow starts at 7am.

09.19.09

..popped in from Buses to take a shower after today's long ass events. Huge thanks to my two special helpers..most definatly couldn't of gotten it done without you!



So, upon raising the beam from full slam-o-matic, the shift linkage operation has become hindered and I haven't been able to get enough clearance to shift into reverse. There are no shocks up front currently, but I opted to go for some gas ones. I have a couple other parts to replace before she can hit the road again. Also still waiting on my adjustable spring plates..

 



11.04.09

So it only took 5 weeks to come, but I finally got the rest of my parts in today..fricken redick!

Here is the main jazz:

I mocked it up, and said to myself..shoot, we need to get even lower back here!  So I modified the arms a little more..before and after.

With them all the way compressed, they match my frame clearance; 0". The little adjusters will allow me to fine tune..

Other then that, got the rest of the parts to mount up the larger dual master. A quick flush and they should be good to go.

..just in time for snow to hit. 

11.06.09

So, the deed is done!

This is where the muffler used to sit:

..and now:

I should mount a small digital camera to the end of this steering box..I'm sure it would be a scary video..pry wouldn't last too long.

Overall, I evened out the rake..mission accomplished. Front to back, I'm still raked about 1.5". Maybe tomorrow I'll pull it out and get some better pictures. 

11.30.09

Took these right before she went away for the winter.

No plans for the winter..we'll see. 

01.22.10

Picked up a rear bumper for this thing..

But on closer inspection, my brackets were not fitting right..

Turned out to be a Bay bumper, so I exchanged it for this guy..

Pretty rough looking, but should clean up decent..and for the price, I can't complain. I think I am going to be ditching the towel-bars and going for the straight euro look on them. 

01.24.10

Tore off the over riders and started cutting away the rust..

Wasn't really cutting it well, so I opted for more productive measures!

BAM!

The finished look..should be starting on the front to match here pretty soon.

The scene..pimpin aint ez.

 



01.26.10

Plans changed..



 



02.18.10

Made some progress in tearing down the carb tonight..



I purchased it fully rebuilt, but all of the jetting needs to be changed for my application.

03.01.10

In semi-related news, I can't seem to keep anything together..

03.03.10

So it took some creative maneuvering, but the bus was set free this afternoon.





Thanks for the help Nicole!  



03.05.10

Made some progress today. Pulled the motor with Darren (3mins, 39secs) and got it up on the stand.

I started getting all rowdy with her, and she was like, "No, this isn't romantic; I'm new to all this!"

Then, we had a talk and she told me she liked me and it was her first time; I was to be gentle and she would let me be with her, so I started up the charm-machine..bow-chica-bow-wow.

Soon I found out that I wasn't her one and only..what a slut.

Now, she gets to sleep in the cold garage tonight..tomorrow I'll be giving her a bath and hopefully start to make a decent woman out of her.

Thanks for the baller hardware Darren, and Tony for the entertainment! 

 



03.06.10

Started the day cleaning off the case..what a mess!

Then it was header time..

Runner mocked up..

Had a few mivers stop by..here's one of them now!

So, the 3/4 side is tacked and ready for a stronger welder. Originally, I was going to use the J-Pipes, but they weren't the correct size, so I'll be needing to order one more U-Bend and a couple more flanges, and we should be good to go on the 1/2 side.

03.11.10

Pulley machined for the trigger wheel:

Here's a before picture for the record:

Popped into the garage to test some things out and cut some more pipe:

Made a reverse style expansion plug for the distributor hole:

Polishing up the main intake pipe now.. 

03.12.10

Tried to pull it out, but the manual says we need to be at TDC, so that'll have to wait till it's off the engine stand.

Made some "headway" on the "header" tonight..

Thanks again for the help Darren!

03.14.10

A little earlier, but as of late I was just working on sleep..

Header? Done.

Ordered up some Silicon, and should be here this week..intake fab'n should commence upon arrival.

03.18.10

Went to the junkyard and found these jewels:

..and wrapped up the night by taking out the stock, and putting in some HD Valve Springs:

Tomorrow I'm going to finish up setting up the intake situation and I've got some fresh pushrod tubes to install.

03.19.10

Out with the old:

And in with the new:

 



03.20.10

Little by little, it's coming together..

Intake pipes are ready for welding:

The wastegate actuator will be moved to this tight spot; nice and out of sight:

Weeded out what's left of the EDIS harness..

I hope to source a few more essentials, (hope to find at Buggy Builders) and then I should be all set.

03.24.10

Made a little progress today with the fuel system. I took a Holley FPR and added a nipple for boost reference:

Add in a matching Holley Pump and we're almost there..

Props to Darren for the fuel tank:

I'm going to be putting this into the split, which will allow me to gain an extra 5 gallons. If I ever do plan on adding a fuel gauge, I have that option without having to cut up my stock tank.

Other then that, I was able to pick these back up from a darling young lady over in Rockford:

Thanks for the welds Joe! 

03.28.10

Picked up some goodies at Buggy Builders, including this New Schadek 26mm Pump. Got back to Darren's and got busy tapping and plugging it for the full flow.

Then it was onto tapping the block..thanks for the tools ZPA.

Done deal..no cracks. Yay.

 



04.03.10

Been making a little progress over the past couple days.

The full flow is buttoned up and ready for some lines:

Broke down and ended up getting a sending unit for my new tank..

Cleaned out the tank, and installed:

But now, where to put the gauges?

Figure this was the best spot, without hacking into the dash or anyplace else. It's a pretty readily available piece should I change my mind, and it doesn't interfere with the fresh-air vent. The fuel and boost are on backorder, but soon they'll be in.

That's about all for now.

03.04.10

UPDATES! 

Completed the FPR..

Started on some bung placement..valve covers and oil return.

And fitted the tins..minus the ones that still aren't here. 36hp Doghouse for $20..can't beat that. Thanks Buggy Builders.

Once they show up, I'll cut them to fit around the turbo header and then everything goes off to powdercoat. 

04.14.10

Went down to Central Iron and Steel and got some scraps yesterday. This is what became of it..



Install'd:

Cover'd:

Free metal and vr sensors in perfect harmony.  



04.19.10

It's all for fitment purposes..wee!



Stuff is at powdercoat this week.

04.23.10

Time to kick it into high gear.

 



05.01.10

Was able to get some things done today. Now that I have all the gauges in, I was able to wire them up and get that done. I actually cut a hole and ran the wires/hose in between the windows..not much room, but it fits.

Got some things back from powdercoat..starting to look like a motor again..sorta.

Other then that, got the fuel pump, pressure regulator, and fuel tank all mounted. Still lots to do! 

05.07.10

Still waiting on a few bits to arrive to finalize the motor, but it's pretty much there. Got started on the wiring for the MJ/EDIS. Pucked up some material and this is what I came up with:

Some test fitting..going to be nice and hidden behind the shroud:

..and onto wiring:

Hopefully I can get it all done and ready for a nice and easy plug-n-play situation when it's time to put the motor in.

05.10.10

Pulley's home..it got the sunk treatment tonight and is ready for some bling-blang. 





Thanks again Paulie & Sir Lans-a-lot!  



05.16.10

Current status:

Cleaning up the front end a bit. Was able to remove the towel-bars and blast the bumper this weekend. Since the deluxe trim is there, I went ahead and got some filler for it to make it look a little more complete.

Before:

After:

 



05.19.10

..whdut?

So, I hate getting all tin-man like after polishing, so I created this..ta da! 

..apple bottom jeans baby.

 



05.19.10

Was able to troubleshoot some things on the truck today and finished installing some goodies..



Loaded a new ignition map and took it on another small voyage. Put a wideband on it and it's running a little lean still, so new jets are on the way. Damn, it's hot out.



Got everything buttoned up and took it for it's maiden voyage. The difference is like night and day. Pulls great all the way to 8psi. 

07.15.12

Time for round three..today's post is brought to you by the number 2000 and the rainbow.







BBQ sauce. 

Time to get busy..





The motor is at a standstill. I sent the bottom end out to get balanced and it turns out my crank was out of spec, so I had to wait for another one to be sent. Got the second one in late last week.

On the good side of things, I did receive these though..

..which came on the same day as these.

I sent the rears out to get widened and re-chromed. My box of meats are on and ready to go. Time to start turbo shopping..