The 1968 Cayman Project

[Jagshund]

I'm getting close enough to having a complete shell to butcher that I thought it time to post a few details of the project here. For those of you who haven't seen the pictures posted in the "Paint & Bodywork: Don't Crush 'em" thread, for the last two years I have been involved in the repair (I really, truly don't think you'll want me to call this a restoration once you read a little further) of a 1968 911L purchased in Twinsburg, Ohio. Having spent nearly two decades under a tarp whilst awaiting some type of divorce or estate resolution, the car was what others would term a 'basket case'. As I'm not smart enough to walk away from a vehicle in need of severe repair, I bought it. My first choice was a strict restoration, a plan that lasted all of a few weeks post-purchase. I would go over every panel requiring attention, but it's much easier to list the ones that didn't:

1) roof
2) decklid

Now, having decided that this car would never be making it to Pebble Beach without resorting to crashing the party, the plans for restoration were out the window. A friend suggested an engine swap . . . as in, swapping locations. I was a little resilient for several seconds, but my resolve finally faded and I agreed. Then the plans got a little crazy as it was decided that, so long as we were making it a midengined car, we might as well make it a watercooled midengined car. Following that, there was talk of the rear suspension coming of a 986 . . . so why not the front suspension? What we're ending up with is a midengined, watercooled 1968 911 with 986 suspension at all four corners. The track width is going to be a 'little wider' than usual to accomodate some of the stock pieces (crossmembers) but the goal is to keep most of the "character" pieces that make an early car different such as the chrome trim pieces.

I've been fabricating and replacing pieces not likely not be replaced during the switch to the 986 suspension (there is some doubt as to the longevity of my fresh "Frame repair pieces, left/right side, to repair torsion tube/jack receiver area in the wheelhouse" which may be going away only a few scant months after being installed). As of now, all major mechanical components have been purchased with the exception of the engine and radiator (Who ever thought you'd see THAT word in this forum?). As soon as I finish installing the new longitudinals and inner rockers the car will be heading to the jig of Huntsville, Alabama's SM Racing Development for the suspension installation and drivetrain mounting points. In the interest of saving space, I'll forgo posting 'before' pictures and refer you to my site (which hasn't been updated since January due to steady work on the car and extreme bouts of laziness). For those of you attending October's RC Ramble, the vehicle should be there during the event (SM Racing is performing the 914 engine removal/installation session) if you want to have a look for yourself. It may be there quite awhile, as I believe Brett & SM have also agreed to help with the tunnel design/installation as well as the new boot. I think that just leaves me with designing and fabricating the new firewall . . .

I will begin posting photos post-suspension install for those curious . . . and will also try to include a few pics/posts in my pp blog (everyone needs one!) about the installation of the 'new' quarter panels sourced from a markedly newer 911 model. I will also need some opinions on an issue I expect to crop up regarding the rear bumper . . .

[ChkbookMechanic]

Good luck! Sounds like quite an adventure.

[turboteener]

Hurry up with those longitudinals and floor pans. Looking forward to getting the car on the jig,

[RWebb]

this sounds exciting

looking forward to seeing pics and diagrams!

[Jagshund]

I will be posting pics as they come; still working on getting the last longitudinal in. As for how the water cooled segment is going to work out, we're going to run the plumbing very similar to that of the 986 & 996 vehicles. A large tunnel with two distinct levels will be fabricated and used as a spine for the pans, which will have a 10" section removed from the center all the way to the engine bay. The coolant hoses will run along the lower level and be protected from road debris by access panel(s).

[Doug&Julie]

Subscribed...I gotta see this!

[jonbot]

Subscribed

[daepp]

Sounds cool. But why water cooled? Is it due to lack of airflow?

[Jagshund]

Originally Posted by daepp

Sounds cool. But why water cooled? Is it due to lack of airflow?

Yes, mostly due to a lack of airflow. I didn't want to run the vented Lexan quarter windows but will likely end up with some type of vents anyway (for intake and engine bay cooling). There are a few different types available, and I'm not quite certain that the "quarter vents" a la 986 would look quite right. Brett has suggested a 1" lip running along the edge of the leading edge of the quarters . . . I'm going to have to see a mockup to be convinced but I'd really like to move some serious air like:

[Elombard]

Hmm the computer/wiring dash will be interesting. Awesome project if it still looks sort of like the original car. I hope you dont have to go to "Gemballa" looking to get all the ducts and stuff in.

I wonder if it would of been easier to stuff a 996 drive train in the rear?

Mid engine is way cooler though. Now I get your Sig, I always wondered what that meant.

[daepp]

What will the firewall look like on the inside?

[Jagshund]

Originally Posted by daepp

What will the firewall look like on the inside?

We're considering the use of a stock 986 or 987 piece so that the access panel can also be used; however, it depends on the final mockup as to whether or not the stock "hump" will clear the accessories, allow for proper seating room and, more importantly (well, driving postition is pretty important too) provide the proper level of rigidity for the car.

[Jagshund]

Thought I'd update the thread before I jump ahead. I finally got the other longitudinal from the fab shop, there was a mix up which almost resulted in me welding in a 16 ga. piece on one side and an 18 ga. piece on the other. Thankfully, I noticed the mistake when picking both pieces up simultaneously (before sweeping the garage; it does pay to keep a clean workspace!). Anyhow, here is the "fit" before I weld them in. The right wide appears .25" off in the pic but it's not . . . the sill plates are just sitting there, so they'll look a lot different once they're in place.

Also picked up an engine, a '99 3.4L with 60K miles and the beginnings of a front suspension. Still looking for 986/996 wheel carriers, wishbones and a crossmember for those of you who might have such pieces lying around. Oh, yeah, might need a tranny case, too, for fit purposes. Anyone have a spare G86 collecting dust??

[Walko]

THis is going to be one very interesting projects

[Tsunamiboy]

Subscribe Oh My

[kcpaz]

sub'd

[Facey]

soooooo friggin cool.

68 cayman i love it!

[9elf]

I was looking forward to someone putting a 996 engine in an older 911.

Never even thought of this.

10 points for what will be the most interesting project in a while.

Please keep us posted.

[av winans]

You've got my attention! Very interested to see this thing develop.

[fxeditor]

I always thought putting a Boxter motor into a 914 would be interesting but this is going to be fascinating to watch!

Good luck with your project!
Michael