Comparison tranny beam
 

Here I fitted them to the section I still have from my donor car. Note, heights are not corrected. I will do this by machining the black spacers. This is just to take measurements for each to get the wanted height, but I show them to get an idea:

http://forums.pelicanparts.com/uploa...1373919464.jpg


http://forums.pelicanparts.com/uploa...1373919507.jpg


http://forums.pelicanparts.com/uploa...1373919541.jpg

Really cool work, Roland - I enjoy reading all of your updates on this project!

Door hinges reloaded
 

I received the aluminum hinges from GT last week. They look nice and are quite well made. The website says "made from high quality billet aluminium", wathever that means, after machining I can say it's not high strength (aircraft grade) aluminium like 6061 etc. more like Anticorodal.

However, against the stock ones, the are not made to fit the stock bushed, but to use with stock pin. As I don't like the idea of this, even if I anodize them when finished, I decided to machine them to accept the bushes. i had to machine off the inner ones and made a seat for the bushes to get 0.10mm of play with OEM bushes fitted

Further I drilled a greasing port for easier maintenance


http://forums.pelicanparts.com/uploa...1374091895.jpg

http://forums.pelicanparts.com/uploa...1374091926.jpg

http://forums.pelicanparts.com/uploa...1374091958.jpg

http://forums.pelicanparts.com/uploa...1374092013.jpg

Form your post i got a lot of information I'm also searching this type of post.

Looks like a spamer...:(

I am very impressed with this whole build you are doing. The attention to detail is just awesome ! I have a grey market 930 here in Florida and slowly doing the same thing while trying to have some fun with it. Watching you remove every gram you can is the way to do it, lot's of little things add up big in the end. Most of the parts and people you deal with we do business with everyday . Keep the posts coming ... we are all looking forward to your first drive.
Kozmo

Big fan, too!
It's like the factory "R" 911 -- if it could be lightened, it will be lightened.

Thanks a lot guysSmileWavy

Just finished removing the "old" PB bushes from the a-arms, was easy to do. Will post pics tomorrow of my homemade special tool. BTW without destroying them!

...and the parts from TK are on the way, so I am never out of work;)

Further I had an idea how to get a better fit for my 2nd generation transmission beam, pics and solution soon

guess we know where
'swiss cheese" comes from

As promissed the ultimate bush-remove-unique-tool;)

BTW made this in workshop, not in living room, just before you guys ask...

Tool is just an old aluminum valve block, which I drilled out to 38mm, same diameter as bushes have. cut a slot and that's it.

As many already know, heat is the way to loose epoxy, JB welds. etc. so I did heat-up on a small hot plate for about one min. full power. don't know the temp, but over 200°C for sure:

http://forums.pelicanparts.com/uploa...1374822943.jpg

Then you have to be quick, to save as much heat as possible. Put a screw driver in the slot, to "open the bore a bit, then you can easely slide it over the bush. Remove the screw driver as soon the block is in position.
Now wait about 30 seconds to let the heat transfer to the bush. This is the point where the chemical structur of the glue is going to be destroyed:

http://forums.pelicanparts.com/uploa...1374823310.jpg

Now clamp the block in the bench vise, so the bush will be hold tight without damaged (not clamp as an idiot, just tight) and while swaying the a-arm you can pull-out the arm. If you remove the glue before it cools down, it comes off quit nice.

http://forums.pelicanparts.com/uploa...1374823621.jpg

And here they are like new:

http://forums.pelicanparts.com/uploa...1374823656.jpg

Plastic door handles
 

After I had contact to Mike Swanson, who makes some RSR replica outer door handles, he is not responding anymore... He agreed to make some for me, but now???



Does anyone know him or what happend to him?

Check this thread too for more info pls:

http://forums.pelicanparts.com/porsche-911-technical-forum/677442-rsr-plastic-outer-door-handle-available.html

What kind of bushings are you going to be using?

Oh I did not say...? Those from RSR products in black. They are on the way to Switzerland from TK together with the Elephant strut mounts (As the Mode ones are obviously only virtually existing:()

http://forums.pelicanparts.com/uploa...1374873953.jpg

I may have just forgotten. :D

Subscribed. Thanks for sharing Roland.

Henry

I am only 41, but I am getting older too;)

While I'm doing my front end I planned on elephants spherical control arm bushing ... any difference then rebels or just by choice ?

I don't think even a pro could tell the difference in performance. The sphericals are just the more complex, more expensive design Chuck came up with so that he wouldn't appear to be directly copying Clint. Just make sure you use the spherical washers with the Rebel Racing kit and you are fine.

Hello Roland

Very nice build and great ideas....

Thanks Rob

I always try to do my best. Sometimes I fail, sometimes I get a good result. But I only show the successfuls here:D

No I am just kidding, of course you will see the failures too, and if it's just to avoid the same mistakes that I did. Luckily that's not that often until today. But I am sure, after I am back on street, some of my homemade solutions have to be improved in a way. We will see...

Since I make a new transmission beam, I thought about get more space for it. This way I don't have to cut away in the middle for the lowest bolt. Here how it looked before;

http://forums.pelicanparts.com/uploa...1375128501.jpg

The idea was to switch direction of the bolt. I drilled the thread away and cut one for a helicoil on the other, but found it too weak. So I cut another bigger thread and machined a seat, so a plug I found could be fitted without standing over:

http://forums.pelicanparts.com/uploa...1375128733.jpg

http://forums.pelicanparts.com/uploa...1375128757.jpg

After I fitted the plug with loctite. Drilling and cut an M8 thread was next. Finally I painted for rust protection:

http://forums.pelicanparts.com/uploa...1375128921.jpg

http://forums.pelicanparts.com/uploa...1375128963.jpg

And here the final result:

http://forums.pelicanparts.com/uploa...1375129070.jpg

Speaking of transmissions, did you see this? ;)

http://forums.pelicanparts.com/porsche-911-technical-forum/762965-worlds-lightest-930-transmission.html

Yes, I saw it earlier today, but to be honest, did not read yet exactly, only watched the pics. Only two gears if I remember correct. But that saves some weight too;)

Roland, I think it is time for you to change the title of this thread from Another Rust Combat, to A Man, His Milling Machine, and Automotive Psychosis! :D

:D LOL

...But I do love understatement, so maybe I change it to "A boy, his file and automotive affection"

So says the guy with the huge (and awesome), self-made tail! :p

Yesterday some goodies from TK arrived:)

RSR A-Arm Bushings and ER camber plates. First what I wanted to know was, if the plates are lighter than my present ones, luckily they are:

http://forums.pelicanparts.com/uploa...1375256856.jpg

http://forums.pelicanparts.com/uploa...1375256875.jpg

BUT the downside is, they have different measurments regarding bearing position. Old one is higher in the part, means when I mount the ER plates, car will be about 8mm higher with present ride height of coilover. This would not be a big problem, but damper rod had to be shorten after alignment, now I have to do this probably again, let's see how mouch I am out of spec then...

However, I have to work on the mounts, as spacer are not made for RSR struts (they fit , but dimensions are not what I like). Will make some out of high strenght aluminum to save some more weight (as usual)

While I am there
 

While I made the "transmission cover bolt turn" I remembered the bulletin with the improved reverse gear fork, because Porsche reported some bent ones. This will cause some binding at shifting into reverse gear.

So I ordered and fitted today. The only difference is the thickness, which has increased from 3.5 to 4.5mm.

http://forums.pelicanparts.com/uploa...1375813850.jpg

Off topic
 

Not for the first time I was asked about my nickname. It's a combination of my last name and the fact, I built streetfighters in my past profession, so here is my own "brand" since more than 20years. This is my first and still my daydriver streetfighter:

http://forums.pelicanparts.com/uploa...1375950973.jpg

I thought Ducati was the originator of the term "streetfighter" applied to a "naked bike" as we call them in the states.

I thought you were a boxer who now was a coah- Prof[essor] Fighter. ;)

The first ones have been conversion in england in the early 80's using sportsbikes. (Racers who did not wanted to replace damaged cowlings on and on, just left them off, later some shops started to built that look.
Ducati used that term about 20 years later...
In my eyes, naked bikes are just without cowlings, could be a touring machine too, streetfighters have to be racebikes, mostly 4cylinder like FZR, GSX-R, CBR,...
Check out Harris, Spondon or MOKO and you know what I mean.

Boxer??? How do you think that?

Good old times ;)

http://forums.pelicanparts.com/uploa...1376003432.jpg

As in "pro-fighter" (professional fighter). I have wondered for years if your name referred to you being a professional MMA guy (seriously)! :D

Bike is probably in better shape currently than the girl. ;)

LOL That's the best I've ever heard about!

So beware of making me angry :D

Bet on that, especially when I rode bothhttp://forums.pelicanparts.com/support/smileys/wat3.gif

So do you also carry a cross drilled, anodized, aluminum knife with you for the times when your MMA skills just aren't enough?! :p

Oh man, that's just too funny! :D

Beside the camber plates, which I anodized black (yes the same old thing, can't resist, as they where that ugly in red) I have nothing to show today.

Conclusion:
Nothing to show....

How about more bikes (or chicks ;))?

OK guys, I feel so sorry to let you into the weekend without anything to dream of:D

It's not finished yet, but almost. Guess what it is:

http://forums.pelicanparts.com/uploa...1376073909.jpg

http://forums.pelicanparts.com/uploa...1376073987.jpg

BTW I made the one on the right;)