Wow! really awesome work.....you got skills my friend..http://forums.pelicanparts.com/support/smileys/clap.gif

Thank you, but I have to say, I have never showed you the rejects;) LOL

@Leichtbauer:

Looks like Säntis at 1st of August (National holiday)

Yeah, you guys rock. Even your cheese is light weight :)

one more DIY part
 

throw-out bearing guide tube (what a long name) raw and then hard-anodized. I know, some of you may now doubt, but I feel pretty comfortable, that there will be no problem, as there should be only little load on it. Further hard-anodized surfaces are quite tough and often used for bearing applications

http://forums.pelicanparts.com/uploa...1363128928.jpg

http://forums.pelicanparts.com/uploa...1363128952.jpg

http://forums.pelicanparts.com/uploa...1363128972.jpg

Roland, wow!
Beautiful, obsessive, wonderful... After busily posting on the "Rear crossmember, tower damage pics" thread I started, followed your links over here, and have been going through it all for over two hours... while nowhere near your level of dedication and patience - or skill - it's always reassuring to know there are others that also spend crazy time working on things some of which no-one will likely ever see again once installed, just because they love doing it.

Form & function... a work of art indeed, in the making, IMO way more interesting than the factory produced leather-everywhere last turbo Speedster featured in the PCA Panorama magazine recently.

Like many others, looking forward to more progress notes & pics as it all comes together.

Will post re coilover mods on the other thread!

Parking brake option
 

I plan to fit a shut-off valve in the rear brake line. As there was none available with M10x1 fittings, I had to machine them. And I found a little weight saving too, the shim which gives the range for lever (black is homemade in aluminum, steel one in silver was before)

http://forums.pelicanparts.com/uploa...1363807316.jpg

Here assembled on the scale, quite lightweight, what you think?

http://forums.pelicanparts.com/uploa...1363807418.jpg

Concerning parking brake I have an issue with street legality. My car is approved with Recaro race seats and 4-point harness. When I am sitting and harness closed, I have no chance to reach parking brake lever. So the fact that I have a Hargett shifter does not matter at all, but I have to remove it, when period approval is made, as they say the shifter is hiding the brake lever. They do not accept the argument of not reaching anyway... Strange world:confused:
However I will remove the whole parking brake system and fix the car with the valve, but have to refit when checking next time. A few kg to save for sure

I just had my mind warped by this thread. Excellent work!

A little time back I worked on the pedal cluster, but was not happy at the end as the bronze bushes I had installed a couple of years ago just aren't like I want. They have way too much play from new (no worn axles/tubes) and they aren't smooth enough. Greasing made them work quiter, but always a mess and dirt catching then.

Now I looked for an alternative, but the measurements aren't regular. So I had to make them myself.

I choosed POM-C, because it's tough, nice to machine and self-lubing. All in all worth a try. Here is the result:

http://forums.pelicanparts.com/uploa...1364406719.jpg

Oops, forgot a pic;)

http://forums.pelicanparts.com/uploa...1364406885.jpg

As I always thought my EFI injector blocks are way too massive, I worked on them now.

Here is the idea. The red areas should be removed:

http://forums.pelicanparts.com/uploa...1365170120.jpg

Because I have no access to CNC machining, a friend of mine offered me to make it in his shop. But no CNC either... The idea is to define several coordinates of the x and y axis to get a bow at the end, which will be machined:

http://forums.pelicanparts.com/uploa...1365170339.jpg

http://forums.pelicanparts.com/uploa...1365170359.jpg

So we spent a long evening in the shop, me announcing the data, he operating the cutter. It took about 30 min for each block:D

No wonder, read this 3times for each block:

http://forums.pelicanparts.com/uploa...1365170521.jpg

However, block fixed on a selfmade bracket to make sure, everyone is machined equal:

http://forums.pelicanparts.com/uploa...1365170581.jpg

And the result:

http://forums.pelicanparts.com/uploa...1365170612.jpg

http://forums.pelicanparts.com/uploa...1365170628.jpg

Due the way we had to make this, surface was not that nice No pic of that mess;), so I will grind a little during this weekend before anodizing

Looks kind of like out current CIS injector blocks, or our revised v2.0 EFI Injector Blocks. :cool:

Love the work you are doing, your passion and commitment for detail and doing it right. And yes, WAY cooler that leather-wrapped this and that.

Thanks Chris!

To be honest, when I was thinking about, your CIS blocks came into my mind too and I borrowed some detail from your block;) and of course stock blocks

First ones finished. I choosed black, as the manifold's black too

http://forums.pelicanparts.com/uploa...1365283198.jpg

http://forums.pelicanparts.com/uploa...1365283225.jpg

Nice work Roland! I keep thinking you have more time on your hands but knowing you don't just amazes me. Plus you got great talent. By chance have your 930 been weighed before you started this project?

Thanks Mike

Yes I weighted the car before starting this time. But some of the work I made before, since I bought the car over 10years ago, I worked on it. When you look at the car in the first post of this thread, then I suggest about 1040kg with full tank. It was that weight a couple of years ago. I made a couple of things since, like RarlyL8 headers and muffler instead of the Schnells and stainless muffler, gas heater mounted, other IC, EFI conversion, etc.. so some weight added and some removed, hard to say how much now. I have no real goal except working on the car and do whatever comes into my mind. Sometimes by all the inspiration from the work of all the others here too

Assembled for checking everything went as wished (and to have a feeling of success:))

http://forums.pelicanparts.com/uploa...1365348628.jpg

http://forums.pelicanparts.com/uploa...1365348656.jpg

http://forums.pelicanparts.com/uploa...1365348678.jpg

http://forums.pelicanparts.com/uploa...1365348699.jpg

Today I finished the pushrod for brake, homemade everything (Aluminum of course;))

Made everything a bit beefier, like the result very much:

http://forums.pelicanparts.com/uploa...1366145060.jpg

http://forums.pelicanparts.com/uploa...1366145083.jpg

http://forums.pelicanparts.com/uploa...1366145104.jpg

http://forums.pelicanparts.com/uploa...1366145128.jpg

I made only right turn threads, but once adjusted, I won't change anyway...

Received my new seat consoles for the Recaros:)

Quite a difference between the steel Recaros and the aluminum ones from Sabelt

http://forums.pelicanparts.com/uploa...1366232185.jpg

http://forums.pelicanparts.com/uploa...1366232215.jpg

And here they are mounted on the seat, like the look very much (not only me as you can see...)

http://forums.pelicanparts.com/uploa...1366232299.jpg

Maybe I should turn the pic next time before posting...

http://forums.pelicanparts.com/uploa...1366232467.jpg

Nice wabbit. Did you shop around for light weight mounts? Which part number are those sabelts you chose? I need to get something for my Tillets and hopefully something light too.

Yes, I compared prices. I choosed Sabelt because I most like the design of all I found. Black anodized and not as heavy looking as the alu Recaros They are expensive as all like Recaro etc... (about 175 USD for one seat), but I did not wanted a no name cheap one, as I doubt the quality (especially when it comes to aluminum)

The part number is Z200005F and they are FIA approved

Visit at the body shop today
 

A few pics of the present status. Reinforcements, sway bar and fuel pump brackets fitted.
One side of rain gutter shaved now, not finished yet. Bigger bracket for passenger floor board, as the rennlines aren't that stable. TB holes in rear fender closed and a bar welded to the fender to reduce fender movement

http://forums.pelicanparts.com/uploa...1366387171.jpg

http://forums.pelicanparts.com/uploa...1366387205.jpg

http://forums.pelicanparts.com/uploa...1366387241.jpg

http://forums.pelicanparts.com/uploa...1366387271.jpg

http://forums.pelicanparts.com/uploa...1366387308.jpg

http://forums.pelicanparts.com/uploa...1366387339.jpg

http://forums.pelicanparts.com/uploa...1366387374.jpg

http://forums.pelicanparts.com/uploa...1366387403.jpg

http://forums.pelicanparts.com/uploa...1366387439.jpg

No updates, at least to show so far, but I was one week off for snowboarding with my best ever girlfriendhttp://forums.pelicanparts.com/suppo...ys/smlove2.gif

http://forums.pelicanparts.com/uploa...1368093374.jpg

http://forums.pelicanparts.com/uploa...1368093408.jpg

http://forums.pelicanparts.com/uploa...1368093432.jpg

http://forums.pelicanparts.com/uploa...1368093497.jpg

Hey Roland...are these pictures from St. Moritz, Zermat or the glacier in Austria near St. Moritz...?? My mom is from Thalvile (sp)...I went skiing at these places yrs ago...I hope to return some day...just breathtaking beauty up there...hope you had a good time...Bob

Hi Bob

It was on the glacier of Kitzsteinhorn Kaprun/Austria

Yes, we had a very nice time. We went there for the 6th time and for sure not the last!

Do you mean Thalwil near Zurich? If so it's only a few km's away from my home!

Hey Roland...cool you were on the glacier...I remember it being surreal when I skied on it as it was a giant slab of ice w/ no snow beyond it...I think that winter...1980 I believe...there was little snow in that area...
Yes you spelt it correctly...thx for that...she lived near the lake...
Nice work on your car here...When I travel to Switzerland, I will email/pm you before as I would enjoy meeting you, seeing your car & workshop too...!!
Thx, Bob

Injury
 

Unfortunatly I pulled apart my lower biceps fibre completly when lifted a box a week ago (was not heavy at all). Had surgery on friday and now a cast for at least four weeks. Then another two months of physiotherapy until I can use the arm as before. The good are that it will be like new after recovery

So I can't do a lot for the next few weeks, as I have only one useful arm for a while, let's see...

wow Roland...I feel your pain & I am sorry to read this...it must of been a bad injury to of had the surgery right away but a good thing so you can start the healing process now rather than latter...
I wish you all the best luck with your recovery & that it be speedy so you can resume your project asap...
Take care...Bob :-)

get well soon!

Yep, get well soon.

Thanks for the kind words guys!SmileWavy

Maybe I can do some more anodizing soon...

received lug nuts. I know, a little bling bling, but had not much choice, as I have conus seat rims. Maybe I cut them anyway a bit and re-anodize in flat black

http://forums.pelicanparts.com/uploa...1369340809.jpg

Further I finished the throttle linkage I drilled. Black parts are selfmade as usual;)

http://forums.pelicanparts.com/uploa...1369340887.jpg

http://forums.pelicanparts.com/uploa...1369340911.jpg

Some little progress
 

While I am still not allowed to use my right arm, body shop sent some more pics

http://forums.pelicanparts.com/uploa...1370591130.jpg

http://forums.pelicanparts.com/uploa...1370591159.jpg

http://forums.pelicanparts.com/uploa...1370591174.jpg

more to see. One side is primered, the other just before. Painter will leave drying at least one week primered before going ahead

And it looks so sweet without rain gutter:D

http://forums.pelicanparts.com/uploa...1371131838.jpg

http://forums.pelicanparts.com/uploa...1371131880.jpg

http://forums.pelicanparts.com/uploa...1371131911.jpg

http://forums.pelicanparts.com/uploa...1371131943.jpg

http://forums.pelicanparts.com/uploa...1371131968.jpg

Looks backdated with the smooth top and I like it.

Nice!

Starting to look like a car again!

While I am still not able to do some serious handiwork, I am looking for some ideas what else to improve. I saw those aluminum door hinges years before and think about them sometimes... But they seem to be a bit overpriced in my eyes:

A pair is 95USD at GT, so 380USD for two doors!

Does anyone used them? Are they good or weak in some way?

Thanks for sharing your thougts:)

http://forums.pelicanparts.com/uploa...1371566784.jpg

http://forums.pelicanparts.com/uploa...1371566793.jpg

Hmmm no one? Ok, I'll buy them anyway;)

@Chris of Turbokraft, are you reading too? Sent you a mail a while ago...

Part needed
 

please check my post:

http://forums.pelicanparts.com/porsche-911-used-parts-sale-wanted/758285-wtb-930-turbo-heat-protection.html

Transmission beam 3rd generation
 

On the search for improvement, I started to made a new beam once more. The first I made was just stock with a few wholes drilled and instead of rubber mounts I welded in shims. Lightweight and stiff it was, but lot more noisy tranny and vibrations:

http://forums.pelicanparts.com/uploa...1373918534.jpg

So I made the 2nd one out of a steel profile and fitted Wevo rear engine mounts. Also I set the engine 10mm lower. On this I used a 9mm spacer between tranny and beam to get enough room for throttle rubber block:


http://forums.pelicanparts.com/uploa...1373918837.jpg

http://forums.pelicanparts.com/uploa...1373918850.jpg

Now I wanted to make one out of aluminum. I spent a lot of time to find a profile, which offers the base dimension I need. Finally I found a squared one with beefed middle section. As I am no engineer, I just compared strenght of the my steel beam material with the aluminum specs, which is pretty the half and trippled the dimension almost: 3.5mm to 9mm plus beefier lower section. Further I decreased the weight saving drilles from 75mm to 53mm:

http://forums.pelicanparts.com/uploa...1373919010.jpg

Sides cut in an angle of 45°, lower 60mm (40mm left) cutt-off and drilled for mounts and some weight saving:

http://forums.pelicanparts.com/uploa...1373919119.jpg


http://forums.pelicanparts.com/uploa...1373919158.jpg