Need help aligning & fitting RSR Flares and bumper.
 

Hi there. I have some RSR flares that I'm ready to line up and "bolt" on to get them ready for welding. I've also got an RSR rear bumper that has no mounting holes. I need some tips on lining everything up to get the fitment right when I weld and paint.

Any tips/suggestions? I searched but (obviously) didn't find what I was looking for. If anyone knows a thread that covers this, let me know.

Thanks!

mike

Sorry can't send you directly, but you might check this thread out for possible pitfalls.

http://forums.pelicanparts.com/porsche-911-technical-forum/331080-put-sc-flares-back-new-problem.html

Thanks Ossi. I suppose I'll take a *bump* as well.

So I'm a little impatient....no one?

I fit the bumpers first. Make your brackets, mount and line up evenly. I get the bumper as sqaure to the body as possible by taking measurements in several locations on each side.

Now line up your flares. It is a balancing act to get a good fit with the bumper ends and centering onthe wheel well opening. You can push the flare in by curling up the outer edge or curl the edge down to move it outwards. Again this is a blancing act to get the best fit. You can use duct tape and spring clamps to hold the flare as you work. Personally, I use Clecos, a spring loaded rivet type of clamp to hold my work. You will need to move, adjust or bend the bumper and flare to make them fit perfectly.

Once the fit is acceptable, use an awl to scribe the outer edge of your flare onto the quater panel. This will be you cut line. I use a body saw, air jig saw basically, to cut just below this line. I then final trim on the line with aviation snips. You want a tight even gap. I leave a small gap to get good weld penetration. I use a file to take down the edge of the flare to leave a .020 to .30-in gap.

I use butt weld clamps to hold the flare in place and then tack it on. I do my fininal wleds using a stitch process, 1/2 to 3/4-in at a time. I immediately cool each weld with compressed air. I then take a hammer and dolly and move the weld back into line with the surrounding surface. When done, carefully grind and finish your welds.

Check out how I did a set of SC flares on my narrow bodied S here. While not RSR, you can see the process.
Fit with bumper extension:
http://thumb7.webshots.net/t/52/52/3...7aMOWCM_th.jpg
Scribe line:
http://thumb7.webshots.net/t/58/58/8...7pjufHP_th.jpg
Butt Weld Clamps for welding:
http://thumb7.webshots.net/t/10/10/0...7edERpl_th.jpg
Welded and metal finished:
http://thumb7.webshots.net/t/54/154/...7FVJLkf_th.jpg
Primed:
http://thumb7.webshots.net/t/48/48/2...7JMESAz_th.jpg

Good luck,
Ed

Thanks evill...very informative. I'm doing the same project only with fiberglass flares. While I need overlapping material, it was still VERY informative. My scariest moment is makeing that first cut!! jack

Yup, once you make that 1st cut, you are committed lol...

If you check out my webshots page http://community.webshots.com/user/evill914 In the Nick Cole 914 album, I did fiberglass flares, you can look at it for reference. Also Mark's 87 Carrera shows a carbon fiber RSR conversion that I did. It uses aircraft fasteners on the flares.

Good luck with your project.
Ed

Ed, great post. That's what I was looking for. In terms of doing the bumper...I guess I just eyeball it first, then measure to hone it in. Then drill the holes in the bumper to mount it, THEN do the flare alignment. Sounds like fun. :)

Does it make sense to have the car on the ground for all this?

Ed, I just went through the whole gallery of the prep for paint, all of the epoxy and spray process. Very informative, thanks!

The only drag was, I never got to see the car finished in it's entirety. Do you have a pic of the signal orange car somewhere?

I am building this car (for myself) right now. What you see in the album are up to date pictures. Stay tuned to see the progress and final results.

BTW- feel free to ask me questions as you do your project.

Regards,
Ed

I use floor jacks, jack stands and clamps to hold the bumper where I want it. Then I measure and mark for bolt holes or to fabricate brackets. I ususally work with the car in the air to make it easier and more acessable. However I always lower the car to final ride height and view from all different angles to be sure everything fits and looks right before I do my final welding or bonding.

Ed

Ed...you're a great resource, thanks.

Were you in the body and paint industry at some point? It looks like you shot that car in a garage, but you seem to have all the right materials and know-how. I thought about the home paint job, but I thought the materials would be too expensive.

In those final pics, it looks like the car was almost a brown color. Were the photos just washed out?

Here is a good description on how it can be done for those using pre-G50 boxes.

http://www.gunnarracing.com/project/rsr/stage15.htm

http://forums.pelicanparts.com/uploa...1172172447.jpg

Tim K

Great info Ed thanks ! i have all the parts to go rsr and i,m not sure what to do. I know i like the carbon job you did a while ago :cool:

Please post your progress here Emptyo great project !

This is a great thread. Ed those photos are of great help! Hope I can send a few questions your way as I tackel the conversion I am doing to my '83 SC.

http://forums.pelicanparts.com/porsche-911-technical-forum/328824-rsr-conversion-part-1-discovery.html

I have been doing custom paint and body work for 24 years now. I used to do it full time, now I do it as a part time business. i doo a few cars and bikes a year.

If you are referring to the Signal Orange 911S, it must be your monitor, this does not look like brown to me:)

Ed
http://forums.pelicanparts.com/uploa...1172190902.jpg

Feel free to a ask.

Ed

WoW thats sweet!! j

Can I fly you to Colorado for a weekend? :)

Mike -

Call Dave Imes at Apex 303-462-2739. He did mine and got them just right. Either hire him to help fit your flares or see if he can give you some pointers on getting them on right. He has flared several cars.