Wow Roland.
You are really stripping that chassis down.
And all the details and great work. Nice thread to follow.

Today I visited my body shop to talk about details, how to go on with the car. you can see how heavy the impact on the donor car was on the RH.

As my car has a lot of deformation, we decided to cut away much more than decided earlier. You can see the roof and rear section, which will be used. Further the outer rear wheel well are open now to see the condition and make some changes.



http://forums.pelicanparts.com/uploa...1357937015.jpg

http://forums.pelicanparts.com/uploa...1357937046.jpg


http://forums.pelicanparts.com/uploa...1357937096.jpg

http://forums.pelicanparts.com/uploa...1357937134.jpg

Looks like you are the Swiss version of Holmes on Holmes but for Porsches not houses......"making it right!"
Looking good Roland.

new weight saving:

Oil plug of tank (still with magnet:) ) I switched from wrench size 15 to 17 for less risk of damage by wrench and choose measurement a bit closer for less play to wrench. As oil tank is black, I anodized plug too in black.

http://forums.pelicanparts.com/uploa...1357996178.jpg

http://forums.pelicanparts.com/uploa...1357996208.jpg

http://forums.pelicanparts.com/uploa...1357996278.jpg


http://forums.pelicanparts.com/uploa...1357996306.jpg

Wow...your car is cut up! Looks like it will be much straighter once everything's done. It seems you have a lots of free to drill out everthing, anodize and now you made a custom drain plug! Nice!

No I am working 40hrs a week as most others too, BUT I am not married:D

BTW, a lot of parts I anodize are custom made or at least machined by myself

Share your expirience please
 

As I do not need heat piping in the rockers anymore, I want to remove them too.

My goal is to remove them at least from rear to the door rest/ A-pillar area like on pic. Is there any downside you made bad expirience. Some structural strength doubts maybe?

Does anyone did this before?

http://forums.pelicanparts.com/uploa...1358185831.jpg

well for the sake of the person you eventually sell the car too. thats one thing i would leave in because it cant be undone with out cutting the car back open.

Not in this life:)

Well, there is everything else missing too, from heated headers to the controls (Black box and in dashboard), piping etc...

hello,

cut it out!
the pipe is not so easy to remove, except you have all other things cut out first.
we have done this on my yellow car - see the elferteam forum ;)

And you use a gasoline heater in this car, right?

Correct, why?

See my thread about gas heater here:

http://forums.pelicanparts.com/911-930-turbo-super-charging-forum/566192-gas-heater-installation.html

I just meant that given your means of heat, that car doesnt't need the OEM side tubes.

On my way to save weight, I worked on the throttle linkage since a while. All parts, except two ball joints are made of aluminum and anodized now, even the hex nut:)

Bracket went dark in cause of it's magnesium alloy, it's anodized colorless.

Further I anodized the brackets for MAP sensor and idle valve and the cap to close the cold start valve hole which I made at my EFI conversion...

http://forums.pelicanparts.com/uploa...1359853841.jpg


http://forums.pelicanparts.com/uploa...1359853980.jpg

so you can anodize magnesium ?

again, really nice work. The amount of time your spending on all these details is very impressive.

Thank youSmileWavy

Yes, I can anodize magnesium. Why not? Anodizing works for aluminium AND magnesium and titan.

I don't know the alloy of that bracket. Because I machined it a few years ago and sandblasted it without any coating after, it went dark after some time. This let me think of a high magnesium percentage. Further the bracket i lighter than expected. I saw newer ones, which are different material for sure

Today I visited the body shop to see, how it's progressing:)

New rear section is fitted, several areas replaced by repair panels and some deformed areas are now flat as new. All chassis checkpoints are now in spec. Next will be A and B pillars "adjusting" to fit door (as the were cut) and adding some reinforcements to avoid cracks due coilover suspension

http://forums.pelicanparts.com/uploa...1360171880.jpg

http://forums.pelicanparts.com/uploa...1360171908.jpg

http://forums.pelicanparts.com/uploa...1360171935.jpg

http://forums.pelicanparts.com/uploa...1360171969.jpg

http://forums.pelicanparts.com/uploa...1360171994.jpg

http://forums.pelicanparts.com/uploa...1360172040.jpg

http://forums.pelicanparts.com/uploa...1360172072.jpg

......now that has to make a guy feel good! :) Looking good Roland.

great progress Roland...keep her rollin'...

Huge weight saving!!
 

I made a new fuel door lock and saved unbelievable 26gr ;)

http://forums.pelicanparts.com/uploa...1360622664.jpg

http://forums.pelicanparts.com/uploa...1360622699.jpg

Further I saved a few gramms with drilling and machining the locking plate, here is the complete unit:

http://forums.pelicanparts.com/uploa...1360622785.jpg

http://forums.pelicanparts.com/uploa...1360622811.jpg

Some little progress at the body shop. new rockers are in, tank support, etc. Heating pipes are completly removed and Ports closed.

Here some pics:

http://forums.pelicanparts.com/uploa...1360972447.jpg

http://forums.pelicanparts.com/uploa...1360972489.jpg


http://forums.pelicanparts.com/uploa...1360972516.jpg

Today I re-assembled the brake calipers. Of course to save some weight here too, I used aluminum fittings. Had to machine them for bigger flow as they where built for Motorcycles and had smaller drilling. Then anodized them black.

Bolts and springs nickel plated and new bridges made. Aluminum bleeder screws will follow

http://forums.pelicanparts.com/uploa...1361061674.jpg

http://forums.pelicanparts.com/uploa...1361061722.jpg

Help needed
 

I need really your help:

I would like to buy really much these lenses:

1965 86 911 912 Porsche Weltmeister Racing Plastic Head Lamp Lenses H4 Clear | eBay

But seller does not ship outside the U.S. and there is no possibility to ask on ebay

Is someone of you willing to buy them and send me? Of course I would pay for everything. Best would be via paypal, fast and safe

Thanks in advance

I can do that for you . . .

PM sent.

I think I can help as well.
You could just buy them and grt them shipped to my us address.
I am expecting to go to a meeting in Rome late may. That way I can mail them from there, or if you cant wait, just ship them here from Alabama.

Thanks for helping :)

PM sent

A Big THANK YOU to Ron for help!

Lenses bought:)

Thank you too for offering help to meSmileWavy

My pleasure!

On my way I made all plugs of the tranny myself. What a PITA to make conical threads on a lathe...

However, here are they on the scale. I will make some pics of them installed and weight the stock ones tonight

http://forums.pelicanparts.com/uploa...1362128828.jpg

Weight saving is quite nice, 162gr :)

http://forums.pelicanparts.com/uploa...1362161511.jpg


And here all fitted to the tranny

http://forums.pelicanparts.com/uploa...1362161581.jpg


http://forums.pelicanparts.com/uploa...1362161619.jpg


http://forums.pelicanparts.com/uploa...1362161645.jpg


http://forums.pelicanparts.com/uploa...1362161677.jpg

http://forums.pelicanparts.com/uploa...1362161713.jpg

Inspired by Leichtbauer I worked on the ignition switch too. Instead of drilling I decided to machine some slots into housing and rod. Housing worked on the lathe:

http://forums.pelicanparts.com/uploa...1362605237.jpg

http://forums.pelicanparts.com/uploa...1362605263.jpg

http://forums.pelicanparts.com/uploa...1362605287.jpg

absolutley amazing here Roland...I guess the question begs to be asked as to what you WON'T do to reduce weight on this car...?? :-) keep up the great work...Bob

Hmm... difficult question... Let me think... Nothing;)

Glad you like my work

Looks awesome.

But, how about removing it altogether and just replace it with a toggle switch of some sort.

Roland, you are an absolute "mad-man" (in a good way - ha!)! :D

Well, my car is not a track car, will use mostly on street and it should stay street legal. Ignition/steering wheel lock is demanded by law here in Switzerland.

... so I fit in a mad world;)

Received aluminum bleeder screws yesterday, saved another few gramms.

Was suprised how heavy the stock ones are, they don't look so massive. New ones are shorter too, fit perfect while OEM are slightly too long in my eyes.

One more piece of aluminum I made, nut for steering wheel hub before anodizing. I saved some more weight (to be honest by mistake:D ) as wrench size is 26mm instead of 27mm

http://forums.pelicanparts.com/uploa...1362862933.jpg

BTW I make almost all parts out of Al Zn Mg Cu 1,5 (7075)

100% Swiss made. The measure of all things.

http://forums.pelicanparts.com/uploa...1362907298.jpg