A more streetable 934 tribute car

[KevinP73]

Here's the challenge.

We wanted to keep the bodywork as authentic as possible and still be able to drive on the street. We had to raise the front end about two inches to keep the front valance off the pavement. This gave the car a four wheel drive attitude that we didn't like. The solution was to section the valance a couple inches and then add a rubber chin spoiler.


The first step was to add a flange on the bottom of the valance that the rubber spoiler will mount to. This will also keep the bottom of the valance flat when I make my cuts to section it.

This is where some careful planning pays off. I can make my horizontal cuts in the middle of the valance on the sides and thru the square opening without any ill effect on the final outcome but if I cut thru the center of the round openings I'll end up with ovals when I'm done. I'll have to re contour the surface below the round opening but I thinks it will be easier than messing with the surface deeper into the opening.


A variety of cutting tools, a lot of fiberglass dust and the sectioning is complete. The cut lines are almost perfectly parallel making re'glassing the two back together much easier.


metal tabs are used where surface alignment is critical.


Both sides of the cut are beveled and taped together on the back side.


The beveled cuts are filled and once the 'glass has cured it's ground flush with the original surface. 'glass, grind, repeat untill the two sections are back together as one. This view also reveals how the taper of the wheel openings are misaligned.


Some creative cutting and 'glassing brings the tapered surfaces back into alignment.

We've been having some unusually hot days here which make working in 'glass especially difficult. You have to back way off on the hardner and then work twice as fast 'cause the resin will kick fast. The heat also opens your pores and allows the 'glass to get in real deep. This is what makes you itch. Repeated showers with the garden hose helps but it makes your neighbors wonder what you're up to.
Updates when they become available.

[KevinP73]

A couple days worth of finish sanding and it's ready for primer.

[heliolps2]

great job , please keep the photos coming,

[GorillaFoot]

Hey, I'm doing a somewhat similar project- what material are you using for protective screens and how did you have them mounted?

[BoxsterGT]

Kevin -

Great job on this front spoiler. I would like to do something similar.

What oil cooler are you using? The opening height seems a bit too narrow for most coolers.

The Setrab cooler I plan to use measures about 6 1/2 x 22.

Len

[rsrfan]

Originally Posted by BoxsterGT

Kevin -

Great job on this front spoiler. I would like to do something similar.

What oil cooler are you using? The opening height seems a bit too narrow for most coolers.

The Setrab cooler I plan to use measures about 6 1/2 x 22.

Len

Len,
Not Kevin, but since it's my car I'll respond. I am running a B&B front cooler
(5 1/2 x 2 1/4 x 24.) As you can see from the first pic, we mounted the cooler up higher than normal to protect from road damage since this is primarily a street driven car. Kevin created a plenum in the fiberglass "cheater" bumper blade which one of the blower motors directs air through the cooler when the engine is running. (The heating/AC systems in the car have otherwise been removed). As such the opening may be narrowed. As a data point, I drove the car over from Kevins shop in Van Nuys to Vegas last July in 110 plus heat and with the front cooler never saw temps rise past the 8:00 position on the guage. As mentioned the car has no AC so it doesn't get much use in the summer heat anyway.

Additionally, Kevin is creating a set of frames to "face mount" the screens in the air dam. It should be pretty trick and I am looking forward to updates as much as the rest of you guys...

[KevinP73]

Originally Posted by rsrfan

Additionally, Kevin is creating a set of frames to "face mount" the screens in the air dam. It should be pretty trick and I am looking forward to updates as much as the rest of you guys...

I considered posting some pics of how I did the screens but didn't really want to see 962Porsche hijack my thread and tell me how he would have done it instead.

[Axiom]

Originally Posted by KevinP73

I considered posting some pics of how I did the screens but didn't really want to see 962Porsche hijack my thread and tell me how he would have done it instead.

Thank you !!

[BoxsterGT]

Any photos of the finished product?

Len

[E Sully]

I have always enjoyed reading Threads by both combatants.
Artists are always sensitive.
How about a truce. 962Porsche stays in his corner and KevinP73 Post some pictures?

[KevinP73]

I'm away from the shop. I'll post some pics of the screens on Wednesday when I get back.

[KevinP73]

A couple pics of the screens.

With no two corners being the same each grille is fit one corner at a time.

The grille are made flat initially. They'll be curved later to fit the flow of the valance later on.

Oil cooler opening was the easiest.
Cell phone pics are crappy. I'll have some better pics later.

Grille is fit and the joint is welded and filed flat. The corners will recieve a little attention also to finish them off smooth.

The face is fled smooth and the screen is installed.

Here you can see just a hint of a curve to match the flow of the valance.



More to follow.

[KevinP73]

[KevinP73]

[KevinP73]

Progress pics.

[KevinP73]

Screens installed

[Axiom]

Very nice work.

How much clearance from the ground do you have now??

[KevinP73]

I'll have pictures of the valance installed on the car soon. I expect to have 4 inches clearance with the lip that is currently on the valance. I also fitted a lower lip that is half the length of whats pictured to give us more clearance if needed.

[rsrfan]

[BoxsterGT]

Bringing this back to the top.

Such spectacular work deserves applause. If available I would buy a valence like this in a minute, at almost any cost.

Len