I had exactly the same thought before assembly but after anodizing. Ground cable will do the trick then:D

Thanks for input anyway. The more eyes, the better!

... and still thinking about the tranny beam color. But even worse, if I choose black should I anodize or powdercoat (to get similar look as the rear beam)? Questions over questions...

Brake Ducs
 

As you can see I have raised spindles , but I think there would be enough room above arm to flip this to other side . http://forums.pelicanparts.com/uploa...1423685857.jpg
http://forums.pelicanparts.com/uploa...1423685908.jpg
I have a support brace on top now so I can't mock that up ;) Kozmo SmileWavy

Kozmo

I will check measurements tomorrow. You are talking about this area, right?

http://forums.pelicanparts.com/uploa...1423691858.jpg

Hi Roland,
Great catching up on your progress after my viewing hiatus - fascinating and awesome as ever.

I note you found a smaller "hockey puck" type horn (Post #409). I changed to similar units for my 911 and one of my motorcycles, and I also fabricated custom aluminum straps to mount them, in place of the so-I-thought cheesy steel ones (one had two thin straps, doubled up) supplied with them... and...

...neither horn worked!!!!, except for a pathetic and somewhat temporary sheep-like bleat. It appears the spring rate/resonant length of the strap is fundamental to the operation of at least some puck horn designs.

Just in case you didn't check your new puck's sound with the new strap - might save you some aggro later!

My favorite non-"what stuff/how do I fix/do this" thread. I look forward to seeing your car in an Excellence magazine spread once you are happy with the number of holes you will have drilled in everything :)

Did Ronknees come a runnin!?!?

CAREFUL! watch yer ba(aaaaaaa)ck... :eek:

^^^ Holy ****! Well done, Paul!

And as a token of my appreciation . . .

http://i.imgur.com/UETIh6a.gif

* Note the Junior High theme that Norm referenced in the POTD tread - hardy har har!

as usual ... Paul and Ronnie up to their best to keep us entertained :p

But to answer your Question ; yes that is the area to measure . That is a 3" hose connection on end hard to get a better shot right now but it has a small turn towards the front as it wraps around . If it were on under the tie rod arm it would slightly turn up, if was over it would slightly turn down . Either way it has a good tight fit pointing towards lower arm .

Kozmo SmileWavy

Barry

Thank you for your kind words!

Your thoughts about the horn are correct. The horn has to be mounted "loose" so it can swing. For that reason I fitted a rubber between horn and bracket, similar to ever horn seen on motorcycles. Of course you cannot expect a deep massive sound of a small thing like this, but it's loud enough and sounds better than you may think.

http://forums.pelicanparts.com/uploa...1423724608.jpg

Ha, I just looked on my Benelli which is the only (of 3) bikes I've owned where I DIDN'T change the puck and so never looked at it... yup, rubber mount... but the other two had springy strap mounts on the stock units. Live & learn, teach me to overthink things!

The screaming of an enraged squirrel is certainly better than a pathetic attempt at an ovine bleat.

One of the most impressive things about your project is how often you had already thought through "potential issues" other Pelicans had in good faith raised... add this minor contribution to that list!

The issues I just don't tell:D

Kozmo

I made some pictures, not the best I guess, cause car is on the wheels and low... Tell me if you need better or different angle:

http://forums.pelicanparts.com/uploa...1423777192.jpg

http://forums.pelicanparts.com/uploa...1423777217.jpg

http://forums.pelicanparts.com/uploa...1423777241.jpg

Roland ; looking at your spindles you have a support brace on the top to like me . So with that said looks like your going to be the test unit for clearance issues . Your anti roll bars are different to , so picture #3 where there is some clearance between body and anti roll bar what is that measurement ? wondering if the hose would fit through there going under your tie rod arm . I might have to make something special for yours but it can be done .Smart racing made some tube wraps that went around lower arms great idea to keep hoses off ground . Have to see about that ;)

Kozmo SmileWavy

Kozmo

I will get some more measurements tomorrow. Guess there is still enough room under the steering arm, but we will see when we know the value.

Have you seen this? Maybe some ideas:

http://forums.pelicanparts.com/porsche-911-technical-forum/443006-carbon-fiber-brake-ducts-finished.html

Honestly this is what got me started ..." carbon ducts finished"... tried to get ahold of him but he just disappeared ???
So I decided to make my own but with a few improvements . Good idea to look at that picture he had a anti roll bar something like yours , appears to be enough room to go in between the body and bar link strut to lower arm . Going under improves the straight alignment of hose to lower control arm angle , less movement . I have both of my fronts off so checking back and forth , side to side is easy . Just wanted to be sure on the measurement between body and bar , I have a 22mm under in stock location not through body .

I also noticed when he ran the hose between the link bar and body it is a tight fit , alittle crunch in hose he pictured

Kozmo SmileWavy

ROLAND... with a few fine cups of coffee, the morning has been invested journeying with you from beginning to present. To think this is a "rust combat" thread... amusing title to say the least given the work you've done. Very impressive and even more so given you're getting things done to the level of craftsmanship you do... working on the balcony... with rabbit companion... home chemical plating & lathe. Fantastic! You also deserve credit for taking the time to take photos, edit, post and comment on them---I know this takes a good deal of time in and of itself. COMPLIMENTS to you all around Roland *****
http://forums.pelicanparts.com/support/smileys/wat6.gif

Thank youSmileWavy

Kozmo

Finally I got the measurements what hopefully help you:

Between side wall and sway bar rod its 60mm. After looking at your prototype I think it should work for me too (port below spindle arm) don't you think? Or where do you see problems with my stock spindles (are they the same height than my RSR ones, haven't checked yet). Maybe the first pic helps for this question:

http://forums.pelicanparts.com/uploa...1424210831.jpg

http://forums.pelicanparts.com/uploa...1424210844.jpg

Could be ok
 

With that measurement you could be ok , a little tight against the body but should fit :) http://forums.pelicanparts.com/uploa...1424571744.jpg
http://forums.pelicanparts.com/uploa...1424571775.jpg
Look close at picture might work for everyone , that is at 90 degree lock left ....60mm you have but , 3 inch is just short of 80mm Kozmo SmileWavy

Kozmo
That's looking very good!

Made some more mods on parts, first the throttle stop from Rennline, way oversized:

http://forums.pelicanparts.com/uploa...1424635141.jpg


Machined-off a lot and made the nut out of aluminum, here right before anodizing:

http://forums.pelicanparts.com/uploa...1424635228.jpg


Also I drilled the front hood latch, made a new pin out of SS A4-80 and the spring holder in aluminum:

http://forums.pelicanparts.com/uploa...1424635435.jpg

http://forums.pelicanparts.com/uploa...1424635465.jpg

http://forums.pelicanparts.com/uploa...1424635511.jpg


And I received my new oil cooler from Patrick Motorsport, lot of work ahead once more:D

http://forums.pelicanparts.com/uploa...1424635618.jpg

Well I will keep at it see what I come up with ;)
finishing up some of the repair areas I made some adjustments , but it fits very nice.

I am still amazed at your progress ... slow but well thought out and designed . I know spring is coming soon so hopefully we will all find out the end weight :p

Kozmo SmileWavy

Roland, when your project is complete it would be nice if you could organize your pictures of mods by system and have everything posted in a sticky on the site for reference on weight reduction. It could be a living document that you could update as you discover any weaknesses in any components (inevitably you will discover a few). I think such a record would be the most comprehensive document on 911/930 lightweight techniques that would ever exist and a real landmark in our hobby.
Good luck and carry on, sir.

Nice idea, but if I had time I would do so much things before... Like spending more time with my girlfriend and my bike:D

Good to know you've got your priorities straight. :)

Kozmo

Found those pics from an earlier discussion about brake ducting. Guess some more inspiration for your prototype possibleSmileWavy

http://forums.pelicanparts.com/uploa...1424879334.jpg

http://forums.pelicanparts.com/uploa...1424879348.jpg

LoL... I have these in save file , but found small ways to improve them. We will see made small adjustment and finish the profile work now . Strange how we are such perfectionist at heart trying to make a good part for my car but seems more then myself are interested ;) ...

Kozmo SmileWavy

P.S.
as someone once said .... " if you can make the swiss watch happy all is good" :cool:
love to see your car with these

Mounted the front bumper to test-fit the oil cooler (or its copy in Styrofoam). Conclusion: not much room. Thinking of cutting much more away than now for air flow and to mount the cooler deeper. Now it's almost at the same line the the front end of the bumper. Maybe I fit the old one until then (next winter:D). Sleeping a couple of nights will help...

However here she is:

http://forums.pelicanparts.com/uploa...1425673719.jpg

Saturday felt a bit like Christmas, received a sending from Mike of AR Concepts. I asked a while ago if someone is making plastic door handles like the 911R but the newer design. He offered me to make some and I am very proud he let me test them and help him with my thoughts and expiriences I'll make to improve the product.

So my first impression:

Finish is nice but not flawless. Regarding the expected customer still good, Here and there some little pinholes and the little sharp seam along the inner edge are the only issues in the visible area and at the part inside the door is still good, only surface is a bit less flat here. According Mike the pin holes are already in the original he made a mold of, so he will have a better mold in the future. Color of them are slightly different, one is a bit darker, but only visible in flash light or neon, almost not at daylight. Weight is almost nothing. Threads are both metal, so no weakness here. The handle is similar to the original, so there is a very thin area where the opening latch is (U-shape). There is some noticeable flex. Think it's no more when mounted, I'll check later... Fitting of lock cylinder without any issue, measurements seems to be accurate to the original. The big question will be how durable it is. Wear due the lock cylinder is one, flex and fatigue breakage are the other possible issues. I leave them raw for testing (sunlight constancy?), but they can be painted for even better finish.

Couple of pics:

http://forums.pelicanparts.com/uploa...1426542234.jpg

http://forums.pelicanparts.com/uploa...1426542258.jpg

http://forums.pelicanparts.com/uploa...1426542285.jpg

http://forums.pelicanparts.com/uploa...1426542330.jpg

Photo of the front valance it too dark (at least on my pc).

Now you got plastic door handles! Have you compared its weight to a stock one?

Pic is possibly to dark, but as there is still a lot to do there maybe better this way;)

Stock handle is 314gr without trigger, lock, etc.. just the casting. Plastic one is assembled like on the last pic (aluminum nut and shim:D) 166gr, so half the weight for sure (naked handle is probably around 100gr)

BTW, don't ask for handles, they are testers until enough expierence is collected and Mike is happy with the results. Honestly I don't know if they will be available once. Maybe he just wanted to stop me asking on and on until I get some:D (just kidding)

Found some time to mount the now finished tranny beam, looks nice I think:

http://forums.pelicanparts.com/uploa...1427060158.jpg

http://forums.pelicanparts.com/uploa...1427060179.jpg

http://forums.pelicanparts.com/uploa...1427060198.jpg


Further I received new studs for the tranny mounting. Did one of you ever replaced them all? Good luck to find the correct ones, parts catalog is not clear at all. In fact, some are missing completely. Even specification is confusing. Two of them are measured without thread length (d x 2) which comes into the crankcase, the other two are including both threads. But even then, they were different with the ones I removed. So I ordered and looked what I get: Two in matt silver, two in that golden plating (which some of you know I, let's say diplomatic, don't like) and those where much to short. I searched for the length I need and found them through the norm named in the specification.

Parts numbers are:

900 060 096 01 M10 X 105mm

900 060 095 01 M10 X 140mm

900 060 099 01 M10 X 110mm (they are from a GT3)

PS, length +20mm thread at case side

However here they are together with the clutch refitted:

http://forums.pelicanparts.com/uploa...1427060701.jpg

Well if there is a traditionel term for unite engine and chassis , then I just underwent an engagement.

Tranny meets engine. Hope they will have a good time together:D

http://forums.pelicanparts.com/uploa...1427315729.jpg

http://forums.pelicanparts.com/uploa...1427315752.jpg

Your car is stunning! Well done! May I ask what exact color that is? I presume it's a Porsche color? If not, may I ask what it is? Thanks!

Well Roland you finally made the Pelican news page , still is good reading after all this time . You have really put together a long wish list for many of us to research and learn from your achievement . Thumbs up ! Kozmo

amazing build.

Wow...wow....I am still breathless....what a imagination...what a engineering feast for eyes...
swiss watches have nothing on you....keep up FANTASTIC work...looking forward for more...

Fantastic color - Venetian Blue?

Iain

I spent my saturday night reading this entire thread. Amazing work, can't wait to see the final weight savings.

Awesome .. Totally !!! Keep posting

About 30 years ago on a trip to visit family in Spiez I sold my skateboard to a guy named Roland. I'd like to think it was you! Wonderful build and amazing attention to detail. I look forward to seeing more as you progress.

It's a VW color, L5Y

Ha nice story. But I wasn't into skateboards, sorrySmileWavy