Narrow Body RSR Style Build

[Evan Fullerton]

So I started this project over 10 years ago after selling my 993 RSR clone. Life, career changes, and finances to finish it have finally sorted them selves out so it's time to get a build thread going again to keep up the motivation as I have been ordering parts like a mad man and working on it every weekend lately. There is now a deadline of having to get it at least painted before I get married or........ it's never going to happen. haha

The 993 was great except for not being street legal, center lock wheels without air tools being a royal pain, and I never bonded with the suspension and steering feedback, motorsports ABS however is pretty awesome.... something I am going to miss a little but it does make you lazy. It was 996 Cup expensive to run and not as fast though. So armed with the knowledge of what I wanted I bought a 1975 911 with a 3.0L and down the slippery slope I went....... again.


Out with the 993.


In with the '75. Knowing what I know now...... I should have just fixed the front suspension pan rust, bolted in a cage, done some exhaust upgrades and been driving it these past 10 years but there is no turning back now.


I was running the 911 with POC doing Time Trials at the time..... and after the 993, stock seats, no cage and 3pt belts didn't seem like the greatest idea.


The Pomona Fairplex Time Trial in 2011 was the last time I drove the car before taking it apart for what was supposed to be a quick cage instal and a few other "while your in there" improvements.



This "moment" was the final straw that I didn't want to drive it again without a cage.

[Evan Fullerton]

Before pulling the motor, went and had a base line dyno to see where I was starting. A whole 167whp!



I don't even want to remember how many days I spent stripping sound deadening and wire brushing off undercoating.



















Ready to go get a cage!

[Evan Fullerton]

Josh at Lucas Fab in Huntington Beach did the cage fabrication.

I will be running coil-overs front and rear and coming from the 993 and being exposed to Cup cars...... chassis stiffness is one thing that is noticeably lacking in early cars. I have always liked the late 80's DTM cars and took that wholistic approach of doing almost a tube fame.









Driver side seat mounts were modified to accept 996/Boxster seat sliders which are very nice.



The cage ties into the front suspension mounting points with stub tubes welded to the 3 nut certs on the front mounting point while the front suspension pan was being replaced.





Hindsight being 20/20 I probably should have put in front camber boxes but now having mocked up all the new suspension, it looks like everything will work out fine.

[Evan Fullerton]

I was working with Tyson Schmidt at the time and he helped me weld on some Carrera fenders that came off of Cory M's race car when it went to 993 bodywork. I guess it was foreshadowing that they were off a G50 car.









Again hindsight being 20/20, I should have made a serious attempt at fitting the Fenn Lane sunroof delete panel before the cage went in but in fitting it afterwards I couldn't get it to line up well enough that wouldn't require a lot of filling and sanding so I sourced a full non-sunroof donor section and after lots of prepping hauled the car up to John Esposito who unpeeled the rain gutter to install it with minimal welding.

[skinnerd]

Looks great.
You made the right decision going with the roof replacement instead of the panel.
What are your plans for the motor? 167hp....ha (just joking)

[Evan Fullerton]

Originally Posted by skinnerd

Looks great.
You made the right decision going with the roof replacement instead of the panel.
What are your plans for the motor? 167hp....ha (just joking)

I've drooled over your car for years Doug! Question for you, did you have to move the firewall on your car to fit the V-ram 3.6 or just lower it a little?

If I was smart, I would have kept the V-Ram engine from the 993. Was a decent bit of kit with Super Cup cams and solid rockers and would have saved me a lot of money.

But alas I didn't so I am building a stupid expensive engine that probably won't make as much power. I'm still acquiring parts and want to have most of them before tearing apart the motor but the heads are with Bill at Xtreme right now and once they come back with a known CC, I can order the pistons and cylinders.

Planned Build Spec
3.2L case
3.0L cross drilled crank
Steel intermediate shaft gear
GT3 oil pump
Pankel Ti rods from a 997 3.6 Cup
Custom Mahle 10.5-1 pistons
LN 100mm cylinders with knock sensor bosses and 105mm case registers
930 RR350 alloy casing twin plug heads ported by Xtreme with larger 8mm stem valves 43/39mm ports, AASCO springs
SuperTech head studs
993 Vario Ram intake with TurboKraft injector blocks. Looks like I can bring the intake down 20mm by machining the adapters lower from my mockups tonight. Bill at Extreme is going to machine them to match his head port work
Motec M150 ECU
1 5/8 to 1 3/4 to 1 7/8 stepped 30in primary headers
226mm Fan with Clewett belt drive
No on engine oil cooler
Amber shroud and tin from Sheridan
993 Oil Tank

Things I still need to figure out are rockers, cams, and ignition system.... thinking of going with 993 Super Cup cams or GT2Evo unless I can get a cam guru to give some better guidance. Are the Pauter rockers worth the cost?

Maybe it will make 300 crank, 270whp? My 993 Vram put down 315whp on a 114 octane tune but had a 5.5in triple plate clutch which no doubt helped on an inertia dyno.

[skinnerd]

Originally Posted by Evan Fullerton

I've drooled over your car for years Doug! Question for you, did you have to move the firewall on your car to fit the V-ram 3.6 or just lower it a little?

TRE Motorsports installed the Vram in my car and we gave the engine bay a bit more headroom instead of lowering the engine.
So the small shelf below the rear window was raised up about 1/2" if I remember correctly.
Unless you look closely and know what you're looking for, you wouldn't catch it I believe.

My Rothsport Vram with RS cams and upgraded ECU made 310hp and 271 ft-lbs at the crank and only requires premium fuel.

Cool build you've got going here....I'll be watching closely.

[Otter74]

Nice build! I look forward to updates.

[Evan Fullerton]

When the car came back from John's with a slick top, that's when the really time consuming and expensive ideas began to take shape.



I got some big wheels.



and having broken the original 2.7L main shaft once with all 167 raging WHP and 205/50/15s.....



...........and enjoying being able to find 1st gear every time. Scope creep now included a G50 swap. Open diff standard G50-01 compared to a Mag Case 915 with a SC main shaft, Guard LSD, Aluminum side cover, WEVO spray bar and aluminum nose cone is a 35lb increase. Once the G50 has a LSD in it, and billet side cover, it will probably gain a few pounds so call it 40 heavier? This car isn't going to be a light weight.



The G50 torque to tube is an additional 7lb heavier before any sleeving of the joint so we are now up to ~50lbs gained...... the price of strength I guess...... not to mention an incredible amount of work.



and while we are at it, lets put in some camber boxes because big wheels and lower then euro ride height, the geometry starts to get less then ideal.



but I am getting ahead of myself.

About this time I finished my Engineering degree and left the motorsports industry to move into the more conventional job market because benefits, 401Ks, and not traveling 20+ weekends a year starts sounding better as you get older. This led to having to find a new home for the 911 but fortunately I have understanding parents and the 911 went to their house and its own shed.







And this is where the project sat for a few years while I helped my Dad restore an old derelict boat on the brink of sinking and sail it across the Pacific to Australia. Anyone else into Old Porsche and Sailing?

[Evan Fullerton]

After restoration in Niuatoputapu Tonga.

[Mixed76]

Boy that took a turn

Sent from my Nokia 7.1 using Tapatalk

[jjeffries]

A beautiful diversion.

John

[ben parrish]

Into both very much...Pacific Seacraft 37?
I’m actually roaming sailboat sites now looking for around a 40-50 foot cruiser for our retirement getaway.

[fanaudical]

I figured the easy way to justify a 911 to my wife was to spend some time shopping for sailboats first (it worked)....

[Evan Fullerton]

Originally Posted by ben parrish

Into both very much...Pacific Seacraft 37?
I’m actually roaming sailboat sites now looking for around a 40-50 foot cruiser for our retirement getaway.

SweetPea is hull number 17 which we believe was the last hull finished by Cruising Consultants before Pacific Seacraft took over the molds. A bit different interior to a Pacific Seacraft being entirely stick built teak but largely the same boat. Built like a tank (and we added some Kevlar to the bow for good measure) and very sea worthy that would click off drama free miles on the windvane. Money no object, a Pacific Seacraft 40 or better yet 44 is on my short list for a world cruiser. The 37 is a bit small inside for anymore than 3 and 2 is better but those 3000 mile passages feel a bit long 4 hours on 4 off for weeks on end. More speed and more crew would make long passages more fun. SweetPea is still sailing around Australia with a young family as her new owners. We picked up a Farr 1104 as a sporty light wind So Cal day sailer as her replacement which also needed a lot of work but that's a story for another thread.



But back to the Porsche. With sailing over for awhile and being employed again as a desk jockey work continued on the 911.

Started mocking up suspension. Out with the old and in with the also old but a bit more serious. Bilstein RSR struts raised 30mm with a 1.5 degree december (which will cause problems shortly) MODE strut tops and 993 Turbo brakes all wrapped with 500lb-in springs.



Bilstein RSR rear shocks with Rebel Racing Hardware and some big springs. Going to try the 500lb-in front, 800lb-in rear to start but it might be a little stiff.... we will see. We ended up with 500lb-in rear springs on the 914 I autocross with a similar motion ratio and that car is significantly lighter with less weight on the rear and much smaller tires and no cage so the 800s might just work ok with really good tires. We will see.



Because of the 8.5in wide front wheels and 245 Hoosier tires...... they need ALL the space in a stock front fender and when you decamber the strut, you loose clearance on the inside so I needed a 10mm spacer to have the tire clear the spring.



This then obviously led to some clearance problems so out came the base ball bat for some massaging. Some day I will have a car that I am happy with the tires size that will fit in the stock fenders but that day has not come yet.



It should have a decent stance. At this height I have 1.5in of up travel front and rear before the tires start running into things.... more on that later.





With that mocked up I decided that fiberglass doors while a LOT lighter are going to be highly impractical (I had them on my 993 also) for anything other then just racing so I got an early door without a door beam and started fitting that around the driver door bars. Took a bit of tweaking but I think I can get there with this door.



Almost looks like a car again but I will soon fix that with some major surgery to the Torque tube area.

[chrisbalich]

Super excited you're doing a build thread.
It's been 3 hours since your last post.
Quit messing around at work and share this story!

[Cory M]

Glad to see the renewed interest and all the progress you've made Evan!

[Evan Fullerton]

Originally Posted by chrisbalich

Super excited you're doing a build thread.
It's been 3 hours since your last post.
Quit messing around at work and share this story!

Work is the only thing that is going to pay for this thing!

Scope creep keeps setting in as now that I'm in this deep....... I am going to be unhappy if it comes out slower then my friend Aaron's 914 I've been driving...... and the 914 is getting pretty fast.



but here is what I have been working on for WAY too long at this point. What a great project to learn to weld on...... it's only the rear suspension! It's been too many years putting off this project because it would mean towing it somewhere and writing a big check so I put on my big girl pants and cut in. What's the worst that could happen, I have to cut it out later and try again......... or the rear suspension rips off.

As with all great projects, it starts with tearing the car more apart and attacking it with an angle grinder.

These 275/35/18 do look pretty big off the car, maybe I should be a little concerned about the ripping off part.



Step 1, cut a gaping big hole in the back seats.



and look at how much work you are willing to go though for a couple more inches.



Step 2, CAD it up because no fabrication is professional grade without a little Cardboard Aided Design.



Step 3, build a jig off the factory pickup points.



Step 4, figure out the MIG welder has no gas flow and the welds look like bird dirt.



Step 5, Rebuild MIG welder gas flow system.

Step 6, Weld some more...... still bird dirt but at least we are getting some penetration.



Step 7, do a lot of measuring, say a little prayer and start cutting.



Step 8, get some tubing to sleeve the inside of the joint with.



Step 9, cut the new tube to fit the hole...... preferably centered.

[skinnerd]

Looking great so far Evan.

[rennch]

This looks fun.