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The Build: MassIVe power with a 5 Speed in my Double Cab
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Mountain Power House



Joined: 26 Jul 2006
Posts: 879
Location: Aircooled Heaven USA


PostPosted: Mon Aug 31, 2009 9:59 pm    Post subject: The Build: MassIVe power with a 5 Speed in my Double Cab Reply with quote

I figured I'd start a build thread for my Double Cab project to share pics and details...




General Specs:
Engine- 2.4 Liter MassIVe Type 4.
Base engine- 2.0 Liter Porsche 914
Crank- 84mm Forged
Rods- 5.325"
Bearings- Pc3 Coated rod, main and cam bearings.
Cam- RAT 9500 series
Lifters- RAT
Cylinders and Pistons- 96mm LN Engineering Nickies with JE Forge Pistons and low tension rings
Heads- RAT 210CFM with 48X38 valves
Compression Ratio- 10.2:1
Exhaust System- 1-3/4" tangerine Racing header coupled to a Phase 9 Silencer
Induction- Pair of 40mm dells with 36mm Vents
Dizzy- Mallory Unilite

Transaxle- Porsche 923 with stock gear ratios, built by Blake Meredith/ Aircooled Technology. Custom chromoly axles.

Brakes- Porsche 944 Turbo on all 4 corners.

Wheels- Still undecided, probably Porsche Sport Design 18"

The subject and description above pretty much says it all.. Stuffing a 2.4 liter, 223HP MassIVe Type 4 engine coupled to a 5 speed, Porsche 915 gearbox... Using as many factory VW and Porsche parts to do the job as possible.. Making the conversion look like something that would have been done at Stuttgart factory is the goal and that means simplicity, effectiveness and a sanitary appearance.

I already have the engine assembled and it spent 3 days in my Dyno Lab, making a peak of 223HP @ 5,500 RPM with only a pair of 40mm Dellorto carbs with 36mm Venturis. The engine uses a 1-3/4" Tangerine Racing Header and phase 9 silencer. The testing was done with a Mallory Unilite Dizzy. In mid 2010 I'll be installing EFI with direct ignition.

The 923 (915) based transaxle is also built and is already installed into the Double Cab after a couple days work last week, Thanks to Danny Bradham and his awesome fabrication skills!



The 923 is a one year only transaxle built for the super rare Porsche 912E. I selected it due to it's gear ratios and strength, as well as the fact that it had a 5th gear that I could actually use in a Truck. I also had one that was in great shape in my stash.

For brakes it's getting Porsche 944 Turbos all around... and more than likely a set of 18" Sport Design rims..

We got started by ripping out the stock 1600 DP that had lived in the truck for several years. It ran OK, but was super slow and I couldn't handle downshifting... So it went to a new home and the 002 transaxle was also pulled (and is for sale) as it's gearing sucked and it didn't have enough forward speeds for a vehicle with MassIVe power..

We then dug up our old Type 4 "Mock up motor" equipped with the very first DTM ever built, coupled that to the original 002 transaxle and used it to make a new product to allow for easy install of the Type 4 into a 68-71 baywindow Bus/Truck... Note that we made sure heater boxes would fit for those who want to Type 4 power their 68-71 bay!






At that point it was time to commit sacrilege and lay the blade of the sawzall deep into the truck... (purists start cringing now) To remove the offending heater duct work that was in the way of the transaxle.




Here it is after being "Raped"...


With that out of the way it was time to have fun, so the DTM equipped mock up motor was coupled to the 923 tranny and lifted into place...



Measurements were taken and a custom mount bar was made for the rear of the engine using Porsche 914 engine mounts. We sat the engine and trans onto the lift table and positioned them exactly where they needed to be while the truck was on the lift.







Up front the factory Porsche 915 trans mount was utilized with the stock transaxle mounts.. Then it was time to fabricate some new mounting pads onto the torsion tube to hold the engine. To do this we'll channel some pieces of 2" box tubing for strength and a nice flat surface to mount the trans mounts to.


With these tacked in place the assembly was rolled out of the way so Danny could Tig weld the mounts into place...









Then we lifted the assembly back up and bolted the entire unit into place.. Amazingly the entire unit was perfectly centered right where the original engine and transaxle had been located..




The final part of this installment finds Danny and I chopping up the OE shift tube to couple it to a Mil Spec fully sealed universal joint..(seal removed for welding in pic)





Then using some 3/4" thick wall tubing we fabricate a shift rod extension that will input gear selections into the factory Porsche "hockey Stick" with precision and smoothness... Before we cut the shift rod length we had to center the shifter (Berg) and ensure the tranny was in neutral..

And here is the completed shift mechanism thats been dropped for the Porsche tranny.



All I need to do now is machine some collars for the universal joints to hold grub screws like the factory VW shift coupler.. Then throw a piece of Manganese bronze into the lathe and turn down a shift tube bushing to support the arrangement best at the transition to the first universal joint.. Then get me axle lengths and the tranny is done and ready to accept the engine..



Thats about it.. More later..
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Jake Raby
57 Oval
64 Porsche 356C Outlaw
66 Bug -The Plague Returns!
73 VW Thing (Will I ever finish it?)
73 Superbeetle (Suby Power!)
76 Porsche 912E (X3!)
79 VW Iltis 4X4
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Jon
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1969 Volkswagen Type 3

PostPosted: Mon Aug 31, 2009 10:07 pm    Post subject: Reply with quote

That is going to be an awesome Double cab. I'll be glad to let you do my Single cab next. Cool
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Mountain Power House



Joined: 26 Jul 2006
Posts: 879
Location: Aircooled Heaven USA


PostPosted: Mon Aug 31, 2009 11:08 pm    Post subject: Reply with quote

Hell, I showed you how to do it!! Do it yourself!
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Jake Raby
57 Oval
64 Porsche 356C Outlaw
66 Bug -The Plague Returns!
73 VW Thing (Will I ever finish it?)
73 Superbeetle (Suby Power!)
76 Porsche 912E (X3!)
79 VW Iltis 4X4
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Jon
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Joined: 01 Jun 2006
Posts: 2414
Location: Bishop GA

1969 Volkswagen Type 3

PostPosted: Tue Sep 01, 2009 6:49 am    Post subject: Reply with quote

Mountain Power House wrote:
Hell, I showed you how to do it!! Do it yourself!


OK Rolling Eyes Laughing
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Mountain Power House



Joined: 26 Jul 2006
Posts: 879
Location: Aircooled Heaven USA


PostPosted: Tue Sep 01, 2009 9:06 pm    Post subject: Reply with quote

I'll trade ya..
do all my lawn work for the next 5 years and I'll install one in your SC!
_________________
Jake Raby
57 Oval
64 Porsche 356C Outlaw
66 Bug -The Plague Returns!
73 VW Thing (Will I ever finish it?)
73 Superbeetle (Suby Power!)
76 Porsche 912E (X3!)
79 VW Iltis 4X4
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Jon
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Joined: 01 Jun 2006
Posts: 2414
Location: Bishop GA

1969 Volkswagen Type 3

PostPosted: Tue Sep 01, 2009 9:46 pm    Post subject: Reply with quote

Hi Jake..I'm Jon, your new yard boy. Cool
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serprice



Joined: 26 Nov 2007
Posts: 349
Location: Statham

1974 Volkswagen Beetle

PostPosted: Tue Sep 01, 2009 10:13 pm    Post subject: Reply with quote

Jon, the price of that lawnmower repair just went way up.
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Shane Price
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Jon
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Joined: 01 Jun 2006
Posts: 2414
Location: Bishop GA

1969 Volkswagen Type 3

PostPosted: Tue Sep 01, 2009 10:28 pm    Post subject: Reply with quote

I believe it is pre-paid. Twisted Evil

Just in case I'll bring my Round-up sprayer to take care of your grass. Mad Whip
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Mountain Power House



Joined: 26 Jul 2006
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Location: Aircooled Heaven USA


PostPosted: Tue Sep 01, 2009 10:35 pm    Post subject: Reply with quote

Ok, so that means the 15 acres at the shop.. 2 acres at the house and 26 acres in Walton County. You can start tomorrow :-)
_________________
Jake Raby
57 Oval
64 Porsche 356C Outlaw
66 Bug -The Plague Returns!
73 VW Thing (Will I ever finish it?)
73 Superbeetle (Suby Power!)
76 Porsche 912E (X3!)
79 VW Iltis 4X4
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Jon
Site Admin


Joined: 01 Jun 2006
Posts: 2414
Location: Bishop GA

1969 Volkswagen Type 3

PostPosted: Wed Sep 02, 2009 6:42 am    Post subject: Reply with quote

I'm going to need a Camper Special in my Westy so I can pull my tractor to all your locations. Very Happy
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serprice



Joined: 26 Nov 2007
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Location: Statham

1974 Volkswagen Beetle

PostPosted: Wed Sep 02, 2009 6:48 am    Post subject: Reply with quote

Oh yeah, I do have a 45mph lawn tractor Head Bang . All you need to do is put the deck back on it. I would wear a helmet though. Yeah i do have to fix your mower if I ever want to sees my tow bar again.
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Shane Price
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Jon
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Joined: 01 Jun 2006
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Location: Bishop GA

1969 Volkswagen Type 3

PostPosted: Wed Sep 02, 2009 7:41 am    Post subject: Reply with quote

serprice wrote:
Oh yeah, I do have a 45mph lawn tractor Head Bang . All you need to do is put the deck back on it. I would wear a helmet though. Yeah i do have to fix your mower if I ever want to sees my tow bar again.


Tow bar.....what tow bar??????? innocent0009
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serprice



Joined: 26 Nov 2007
Posts: 349
Location: Statham

1974 Volkswagen Beetle

PostPosted: Wed Sep 02, 2009 8:15 am    Post subject: Reply with quote

Happy Role Happy Role FU
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Shane Price
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Mountain Power House



Joined: 26 Jul 2006
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Location: Aircooled Heaven USA


PostPosted: Fri Jun 17, 2011 8:58 pm    Post subject: Reply with quote

Finally!!
I drove it home tonight... Its astonishing! 5 Speeds, cruising at 80MPH, EFI and 215HP!

This thing is un real.. so smooth, power on demand and it runs head temps less than 350 all the time..

Have a little more EFI tuning to do... From the Driver's seat!!

The drivetrain is all complete, now for the 944 Turbo brake install :-)
_________________
Jake Raby
57 Oval
64 Porsche 356C Outlaw
66 Bug -The Plague Returns!
73 VW Thing (Will I ever finish it?)
73 Superbeetle (Suby Power!)
76 Porsche 912E (X3!)
79 VW Iltis 4X4
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View user's profile Send private message Visit poster's website
serprice



Joined: 26 Nov 2007
Posts: 349
Location: Statham

1974 Volkswagen Beetle

PostPosted: Sat Jun 18, 2011 9:33 pm    Post subject: Reply with quote

Hell yeah! Now thats a shop truck Very Happy
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