Give it a go: 76 911 Project

[Alexandphoto]

Hi all!

New to the Pelican Parts Forum and thought it would be cool to create a build thread. I haven’t made one before as everything seems to be Facebook based these days. It’s great to see such an active forum community.

A bit about the car:
It’s a 1976 911 S originally delivered to California and still retains its marching numbers 2.7 CIS motor.

It made its way over to Australia in the early 90s and was converted to right hand drive. I bought it in November 2020 off the second Australian owner, and he had owned it since the late 90s. I flew down from Sydney to Melbourne with a friend and drove the car back on the same day (about 600 miles).

Unfortunately, there is not much in the way of documented service history, however there is paperwork for the timing chain tensioner being upgraded in 2019 by Porsche Melbourne which was a big win!



Upon return I put together a list of parts and gave the car a basic service.

Since then, the notable changes I’ve made:
- Installed front fender oil cooler (Mocal/Setrab kit)
- Repainted the wheel centre’s to black (the polished look wasn’t for me!!)
- Replaced the aftermarket steering wheel with a Momo Prototipo



Some maintenance items I’m currently working through:
- Replacing all brake soft hoses with braided lines a local brake shop made me
- Installing rebuilt brake master cylinder
- Replacing front sway bar bushes
- Replacing front tie rod ends
- Replacing brake fluid reservoir (old one was dirty and tired)

Being in Sydney Australia, we are currently in lockdown due to COVID. Whilst waiting on parts, I decided to make a start on changing over from heat exchangers to headers. I’ve also had a custom exhaust made up which should sound great!

However, upon removing the heat exchangers I noticed that the fuelling is inconsistent and some cylinders are running leaner than others (white deposits/coating inside the exhaust tubes).

Carbs have been on the list as a “nice to have”, but I have decided I will go ahead with them now rather than trying to fix the CIS system.

So after I finish up the above maintenance it will be onto:
- Finish the wiring for the SPAL oil cooler fan (it’s installed, but not wired up yet)
- Carburettor conversion (leaning towards Weber 40s currently)
- WEVO short shift kit (already have this on standby)
- RS Door cards and new seats (the interior has been retrimmed in a carpet style fabric that whilst comfortable, isn’t a great look. I’ve sourced replacement leather rear seats, and I’m not sure whether I’ll retrim the front seats or install recaros.)
- Potential wheel swap. I’ve purchased a set of SSR formula mesh and also some BBS RS. My plans were to swap over to one of those sets eventually (both need refurbishing), however after painting the Fuchs I’m torn.
- a lot more driving!!


Thank you if you’ve read this far! I’ll try post up any updates as I go

A few extra photos below

[Alexandphoto]

Always remember things after hitting publish!

A few extra bits:

- Fixed an issue with the high beam contacts/switch
- Flasher relay replaced
- LHS front headlight replaced due to cracked glass
- Heater hoses replaced (although I will be removing them again soon for the carbs!)
- Pedal bushes replaced (some had worn through entirely and had notches... not good at all and made for a terrible pedal feel)
- Bumper smile replaced

Just posting that list up for my own future reference too

As you may have realised by now, there is a lot of little bits and pieces to be done and I suspect some maintenance was neglected sadly. But that’s what has inspired the thread name, I’m trying to turn that around!

[ian c2]

Welcome to the forum
Congratulations on your new car

[Alexandphoto]

Originally Posted by ian c2

Welcome to the forum
Congratulations on your new car

Thank you Ian!

My first Porsche so I’m still finding my way around, but very very excited.

[ian c2]

What is the hole partly covered with tape in the wheel-well ?
Did it used to have remote reservoir shocks ?
Or is that for abs and pad-wear wiring ?

[psychoideas]

Originally Posted by ian c2

What is the hole partly covered with tape in the wheel-well ?
Did it used to have remote reservoir shocks ?
Or is that for abs and pad-wear wiring ?

They will be holes that carried the A/C hoses back when it was a Left Hand Drive.

[psychoideas]

Originally Posted by Alexandphoto

Always remember things after hitting publish!

A few extra bits:

- Fixed an issue with the high beam contacts/switch
- Flasher relay replaced
- LHS front headlight replaced due to cracked glass
- Heater hoses replaced (although I will be removing them again soon for the carbs!)
- Pedal bushes replaced (some had worn through entirely and had notches... not good at all and made for a terrible pedal feel)
- Bumper smile replaced

Just posting that list up for my own future reference too

As you may have realised by now, there is a lot of little bits and pieces to be done and I suspect some maintenance was neglected sadly. But that’s what has inspired the thread name, I’m trying to turn that around!

Welcome,
I too have a 1976 ex Californian car. Done heaps of mods but right now working on ITBs with MS2.

Oh, And I'm in North East Victoria. Sort of near Albury.

Cheers,
Frank

[Alexandphoto]

Thanks for the warm welcome!

Interesting point about that hole, it’s something I was curious about too. My 911 has no AC and was not originally optioned with AC (I believe), so I’m not sure if that’s it. From memory, the LHS also has the hole but I would need to double check.

[jaycee1977]

Great stuff mate, thanks for sharing, reminding me that I should start my own build thread, currently just on Instagram (@porsche_9e11 if you're interested). I'm in Sydney too and working on bringing my first Porsche, a '77 Targa, USA car back to life after someone had harvested a bunch of the juicy bits from it. Maybe see you at a cars and coffee some time. JC

Sent from my SM-G998B using Tapatalk

[kach22i]

Originally Posted by Alexandphoto

.............I decided to make a start on changing over from heat exchangers to headers. I’ve also had a custom exhaust made up which should sound great!

I'm not sure what I am looking at, but it sure looks interesting.

Please post more once installed.

I'm still in the process of removing weight from my 1977, took over +250 lbs out of it.

Took a huge step backwards today when I had a +250 lbs passenger in it.

All the fun got drained out of the car instantly, I was rather taken back.

You have a very nice car and are on the path to making it nicer, congratulations.

[Alexandphoto]

Originally Posted by jaycee1977

Great stuff mate, thanks for sharing, reminding me that I should start my own build thread, currently just on Instagram (@porsche_9e11 if you're interested). I'm in Sydney too and working on bringing my first Porsche, a '77 Targa, USA car back to life after someone had harvested a bunch of the juicy bits from it. Maybe see you at a cars and coffee some time. JC

Sent from my SM-G998B using Tapatalk

I’ll give you a follow! My Instagram name is the same as my name on this forum.

Looks like there is an interesting twist to your build. Will be great to see it in the flesh someday

Originally Posted by kach22i

I'm not sure what I am looking at, but it sure looks interesting.

Please post more once installed.

I'm still in the process of removing weight from my 1977, took over +250 lbs out of it.

Took a huge step backwards today when I had a +250 lbs passenger in it.

All the fun got drained out of the car instantly, I was rather taken back.

You have a very nice car and are on the path to making it nicer, congratulations.

This was a custom exhaust a fabricator friend made up for me, but it’s a bit loud currently so we’re making some adjustments to it. It is an equal length system and when partnered with the European racing headers I’ll be putting on, my exhaust will be equal length the whole way through. Hopefully it gives it a nice note!

911s on a diet seem like a blast. What areas did you take weight out of to shave that much?

[kach22i]

Originally Posted by Alexandphoto

911s on a diet seem like a blast. What areas did you take weight out of to shave that much?

It might be considered a major deviation from your plans so I hesitate to introduce you to the additive weight loss methodology. In short there are many threads on this topic, and it isn't any one thing you can do, rather is is a philosophy one embraces with semi-religious dedication required.

With these cars going up in value any deviation from stock may lower the value.

With this in mind, is your car a historic time piece or closer to a disposable toy fit for desecration?

The usual sacrifices to the pagan God's of Light Weight are A/C and heat, followed by increased sound levels and decreasing discomfort. The most ardent devotees put their very lives on the line with fiberglass replacement parts. They are the high priest of the movement.

[Alexandphoto]

Originally Posted by kach22i

It might be considered a major deviation from your plans so I hesitate to introduce you to the additive weight loss methodology. In short there are many threads on this topic, and it isn't any one thing you can do, rather is is a philosophy one embraces with semi-religious dedication required.

With these cars going up in value any deviation from stock may lower the value.

With this in mind, is your car a historic time piece or closer to a disposable toy fit for desecration?

The usual sacrifices to the pagan God's of Light Weight are A/C and heat, followed by increased sound levels and decreasing discomfort. The most ardent devotees put their very lives on the line with fiberglass replacement parts. They are the high priest of the movement.

It is an area I’m both curious and nervous about for the sentiments you’ve shared.

With this car I do plan to deviate from stock in a few different ways, however my main concern is sacrificing drivability and comfort. So probably not the right fit for a lightweight diet!

I’m currently in the process of removing the heat, but I must admit I do wish I had AC for the Australian Summer.....

[jaycee1977]

Originally Posted by Alexandphoto

It is an area I’m both curious and nervous about for the sentiments you’ve shared.



With this car I do plan to deviate from stock in a few different ways, however my main concern is sacrificing drivability and comfort. So probably not the right fit for a lightweight diet!



I’m currently in the process of removing the heat, but I must admit I do wish I had AC for the Australian Summer.....

A mate has a Classic Retrofit electric AC system en route from the UK now. I'm sure he'd be happy to show it off if you decide AC is needed.

Sent from my SM-G998B using Tapatalk

[kach22i]

Originally Posted by Alexandphoto

It is an area I’m both curious and nervous about for the sentiments you’ve shared. .....

I don't think that I've really missed anything that I've removed......................too much.

A/C including all the hoses, condensers etc....
Smog pump (only thing a shop did).
Heat stuff, including hoses, blowers, fans in front trunk and engine bay
Rear bumperettes
Rear seat insulation and the rear seats, rear belts
Insulation inside of engine bay
Stereo and speakers
Rubber trim on bumpers, front and back
Lower trim (metal and rubber) on sides of car
Front trunk carpet.
Center console
Partially cut off deteriorating heat exchangers, still getting to the flappers.
Charcoal canister
Went from phone dials to Fuch wheels
I don't carry many tools with me anymore, and I've lost weight around my waist

Things to do:

Headers plus + light weight exhaust (you will see.....takes time)
Windshield washer reservoir in left wheel well (heavy when full), plus pump.
Install light weight racing seats that I've customized, sitting in shed all summer
Vent holes in rear bumper (mesh infill) and maybe front bumper (acrylic insert)
Carpet and floor mats to be lightweight perlon or other
Doubt that interior floor coating will be removed but it's an option.
Lexan/polycarbonate rear targa glass (someone's done similar)
Keeping steel hood but could do fiberglass rear deck without lowering safety I guess.
I have plans for a lighter targa roof, LOL I can dream big
Alum crush tubes plus trim & tuck in bumpers
Rear light buckets, someone gotta 3D print me some -cheaply please
Get some small rust holes fixed, more will show up when glass is replaced for painting I assume

............like I said, fewer creature comforts, more noise and more fun.

Staying away from fiberglass parts on a street car for safety reasons and for cost reasons (I'm frugal).

I've kept all the parts that are salvageable or of worth if anyone wants to add 300 lbs back on. I kind of stopped counting at 242 lbs and have to weigh a box or two to get caught up.

[Alexandphoto]

Originally Posted by kach22i

I don't think that I've really missed anything that I've removed......................too much.

A/C including all the hoses, condensers etc....
Smog pump (only thing a shop did).
Heat stuff, including hoses, blowers, fans in front trunk and engine bay
Rear bumperettes
Rear seat insulation and the rear seats, rear belts
Insulation inside of engine bay
Stereo and speakers
Rubber trim on bumpers, front and back
Lower trim (metal and rubber) on sides of car
Front trunk carpet.
Center console
Partially cut off deteriorating heat exchangers, still getting to the flappers.
Charcoal canister
Went from phone dials to Fuch wheels
I don't carry many tools with me anymore, and I've lost weight around my waist

Things to do:

Headers plus + light weight exhaust (you will see.....takes time)
Windshield washer reservoir in left wheel well (heavy when full), plus pump.
Install light weight racing seats that I've customized, sitting in shed all summer
Vent holes in rear bumper (mesh infill) and maybe front bumper (acrylic insert)
Carpet and floor mats to be lightweight perlon or other
Doubt that interior floor coating will be removed but it's an option.
Lexan/polycarbonate rear targa glass (someone's done similar)
Keeping steel hood but could do fiberglass rear deck without lowering safety I guess.
I have plans for a lighter targa roof, LOL I can dream big
Alum crush tubes plus trim & tuck in bumpers
Rear light buckets, someone gotta 3D print me some -cheaply please
Get some small rust holes fixed, more will show up when glass is replaced for painting I assume

............like I said, fewer creature comforts, more noise and more fun.

Staying away from fiberglass parts on a street car for safety reasons and for cost reasons (I'm frugal).

I've kept all the parts that are salvageable or of worth if anyone wants to add 300 lbs back on. I kind of stopped counting at 242 lbs and have to weigh a box or two to get caught up.

Wow! Thank you for sharing this. There’s definitely bits and pieces I think I will consider for my car, although I’m hesitant to go as hardcore as you have done. Would be a very fun drive, but the balance of drivability and creature comforts is very delicate for me with this car.

Have you considered going titanium for your exhaust? Expensive I know, but the weight saving is incredible. On another of my cars the catback alone was about 1/3 of the weight of the factory catback. And the sound.... amazing!

[kach22i]

Originally Posted by Alexandphoto

Have you considered going titanium for your exhaust? ..........

I don't mean to tease, but I also don't want to be ridiculed before I even try this exhaust experiment I have in mind. It's so simple and cheap I cannot believe no one's tried it before, maybe they have but were too embarrassed to post their failure?

I'll probably add heat via heat pad under the removable cushions of the race seats.

Then if ambitious, try a second battery (a tiny one) dedicated for an electric heater used on ultralights and RV's. Would charge via trickle charger after every use as to not overload my car's electrical system, would be 100% independent and good for around 2 hours of use.

[Showdown]

I looked at a few titanium mufflers but the weight savings wasn’t in accord with their cost. I went with an M&K 11# muffler, a significant savings over the original sausage.

[Alexandphoto]

A big update! I managed to find a set of Weber 40IDAs that came off a 2.7

Unfortunately the condition isn’t as nice as expected and I was hoping to get away with just a gasket kit, looks like I’ll need to be a bit more thorough. Something to keep me busy!

[kach22i]

Originally Posted by Alexandphoto

A big update! I managed to find a set of Weber 40IDAs that came off a 2.7

Unfortunately the condition isn’t as nice as expected and I was hoping to get away with just a gasket kit, looks like I’ll need to be a bit more thorough. Something to keep me busy!

As I understand it, you will get more low end grunt, worse gas mileage and have to learn a cold weather staring technique.

However I've never read of anyone removing the carbs and going back to CIS.

Congratulations.

EDIT:

Found an old thread that I bookmarked.

438 lbs gone in 5 days - My Build Story
https://forums.pelicanparts.com/porsche-911-technical-forum/423361-438-lbs-gone-5-days-my-build-story.html

Please keep in mind that I am not going weight loss crazy. I am not stripping undercoat, or drilling holes.

There is someone in the forum that had fiberglass parts including their rear bumper on their street car. When him and his wife got rear ended they both ended up with long term health issues, mostly the back. He felt it was a mistake, and keeping the original aluminum bumpers would have resulted in less damage to the car and their bodies. Buy hey, some people ride motorcycles, so there you go.