This thread is a credit to all the people on the forum that helped this project along! Tonight, my son and I turned the key and had the shock of our lives. It didn't hardly even crank but rather fired instantly. The car had sat for 1.5 years and the engine for 3 months:

Donor Car #1 1984 300DT totaled (donated the engine)
Donor Car #2 1983 300D manual euro (parts car) (donated drive shaft and flywheel)
Chassis #3 1982 240D manual 4 speed (donated tranny & chassis)

I wish I could thank all of you individually but the list would be forever. Its simply incredible to be a part of a helpful community like this.

I suspect that I'll have some bugs to work out, but the engine sat there and purred like a kitten. Still need to put calipers on and bleed the brakes and clutch master cylinder.

Project cost:

1. received $500 from insurance for totalled car
2. paid $400 for 240 with siezed engine
3. bought new belts, pilot bearing and front calipers

Thanks again,

Don

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DAILY DRIVERS:
'84 300DT 298k (Aubrey's)
'99.5 Jetta TDI IV 251k (Julie's)
'97 Jetta TDI 127k (Amber's)
'97 Jetta TDI 186k (Matt's)
'96 Passat TDI 237k (Don's
'84 300D 211k Mint (Arne- Undergoing Greasecar Conversion)

SOLD:
'82 240D 229k (Matt's - Converted-300DT w/ 4 speed

Diesel Don,

See, I told you the old fuel would not be a problem.

P E H

Congratulations!

Which final drive did you use? If you stuck with the 240D differential please post your impressions of overall performance running through the gears.... am especially interested in top end perfomance - 95mph?

Cooooooool


Good work buddy!

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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

Don,
Is there any way you can post pictures of that rear engine mount and how it is now attached to the body?

This same conversion is about to be performed on the lovely and charming Marlene. I'd like to see how you solved that issue.

__________________
Never a dull moment at Berry Hill Farm.

As soon as you get all the bugs worked out, take it for a lap around the country, and let us all have a turn driving it!

Congratulations.

__________________
Rick Miley
99 E300 TurboDiesel
82 300D Euro
05 Jeep Liberty CRD
00 VW Jetta TDI
Former MB: 86 190E 2.3, 87 300E, 80 240D
Chain Elongation References

P.E.: You were right about the fuel and I sure am glad. That would have been another mess draining all the old stuff. Thanks for the multiple help along the way.

Diesel Dog: I suspect that I'm going to want the differential from the 300 chassis. I had this one half apart and probably should have gone through with it. However, I did learn about axle shafts and how easy they come out, etc. I'm a bit nervous at what it will be like at high speeds. On the other hand, its for my 16 year old son and if it sounds like its going to break at 80 mph, that might be good for a year or so.

R Leo: I'll write down to snap a digital of the rear tranny crossmember. However, in theory, it was simple. Whether or not it holds is another issue. Remember that in moving the tranny back exactly 4" (because of the 5th cylinder), that the chassis underneath tapers inward. As a result the holes in the crossmember were to wide. So I drilled holes at exactly 13.25 inches apart rather than the 14.5". This allowed me to use the same crossmember. I may have weakened it substantially though. Will keep an eye on it.

Rick: Not only should I tour the country and let you guys drive it. I should loan it out six months at a time for all the help I received.

Thanks

Don

__________________
DAILY DRIVERS:
'84 300DT 298k (Aubrey's)
'99.5 Jetta TDI IV 251k (Julie's)
'97 Jetta TDI 127k (Amber's)
'97 Jetta TDI 186k (Matt's)
'96 Passat TDI 237k (Don's
'84 300D 211k Mint (Arne- Undergoing Greasecar Conversion)

SOLD:
'82 240D 229k (Matt's - Converted-300DT w/ 4 speed