SWB 911R...the beginning

[911 tweaks]

Lars... you are a TRE of the Mid West... a CNeilson... a Henry Schmidt... a I don't know what else to say but truly a professional craftsman AND enjoying what you do for sure as it shows!!
I hope you do the book as it would be great reading...
Carry on man as I hope this continues until it has been road~track tested and we all can see how she does per your intended uses.
Thanks once again for sharing your well done and well presented story of your creation!
Bob

[speedo]

I really don't want to un-install the tank again. Everything is ready to be buttoned up...so I hold my breath that everything works as planned and fits. I install the tank...

I run the drain through the body...and the vent per Grady's suggestion up and and over...behind the instruments, back down the passenger side and into the smugglers box to vent

The other side

I am finally installed on the topside....I still need to connect the fuel lines/plumbing on the bottom side

[Facey]

this build is amazing.

[speedo]

The door window tracks need to be installed...the new channels and rubber trim from our host have arrived. As soon I get the tracks installed, I can roll the beast out of the garage and wash him for the first time...as he will now be "water proof".

I need to connect the tank-pump-lines in the steering tunnel as well as the brake lines to the master cylinder.

Getting close to the "no excuses" day to start checking out the systems...oil, fuel and electrical.

Speedo

[rennch]

Lars...it looks fantastic! Looking forward to many mountain drives this summer.

[rennch]

Lars...it looks fantastic! Looking forward to many mountain drives this summer.

[speedo]

Early material used in the window tracks was a sort of woven material. Mine is disintegrating and needs to be replaced. At the same time I will replace the little quarter window rubber as it is dry-rotted and cracked. This cannot be done with the tracks mounted in the door...obviously. Looks like the easiest way is to completely disassemble the window tracks...

In the disassembly process...had a mishap. The pin that sits in the upper hinge snapped on the drivers door. This is the underside of the frame (top of the hinge) where the pin "froze" and sheared

And the top of the window (bottom of the hinge)

I'll have to drill out the pin and repair. This old window guide is tough to remove. It has a metal skeleton and was glued in well


Everything apart and stripped of old glue

Not bad weather working outside given the amount of this...

...surrounding the shop.

[speedo]

I'll need to drill out the pin from both sides of the hinge

The pin is connected to the lower half of the hinge on the vent window. It measures 4mm so I will undersize the hole

tap it..

And use a 4mm steel screw as the new pin

Fixed and compared to the drivers side which I didn't destroy in the disassembly

New rubber for the vent window


And new velvet/rubber for the window track...I realize it is hard to see...but it is in there.

The passenger side took 3 hours...I kept getting ahead of myself and had to un-assemble the frame a couple times. The drivers side took 20 minutes. I had time to semi-install the drivers frame...passenger side is ready to go

I'm liking the "bling"...this is new for me as I am used to things being blacked-out.
Passenger side next, as well as interior door panels which are fit, but waiting to be installed.

[EarlyPorsche]

Incredible. And its funny because I really disliked the door handles when you first showed pictures of them but on the car they look like a factory lightweight option or something and look like they were a factory option!

[village idiot]

Thanks for the edu on the window frames I have to do this as well on mine.

[sc_rufctr]

I think this thread is great. So much info... Well done

[rennch]

I had such a hard time with those window rubber channel pieces. Lars, does your car have the chrome window trim that snaps on to the top of the door and provides the squeegee for the window? It took me *forever* (and a lot of silicone lube) to get those in. You probably have some super technique though.

[cnielsen]

Looking good Lars, looks like it is a race to the finish for both of us!

I just finished this same job today.

BTW, the window channel material that you removed is the original type and Stoddard is the only source where I could find it. You probably noticed the "hard channel" was on the top and rear section of the window frame, while the front was the traditional "soft channel."

The hard channel is quite a bit deeper than the soft channel to compensate for the shape (depth) of the early door frames. I believe they probably changed this in '69.

It looks like you replaced everything with "soft channel" which works fine but that is why it "dissappears" in your one picture.

Just wanted to point it out for anyone interested...now please, carry on

[Tom '74 911]

Lars - a great project.

Where did you source the electrical wiring from? It looks like new wiring in stock colors?

What foam seal did you use at the front and rear bumpers?

Looks fantastic - all of it.

Tom

[speedo]

Same as the driver side....but I only plan to install once. Not to bore you with the trials of the drivers side, the window frame was installed eight times. Anything that could go wrong did. The later window channel from our host (not Pelicans fault) allowed the window to drop out of the track. It was not thick enoughto hold the window tight. Word to the wise...if using the later 1965-1989 window channel on an early car...you need at least a 1/4 inch of material behind the rear track...you are essentially "furring the channel " forward. I did this and reglued the channel and reinstalled it....checking the fit with the door closed...perfect. Now to install the Appbiz early door panels. But wait, I need to install the modified release mechanism. Unfortunately, with the window track in place this is not possible...bummer, window frame comes out again. This is starting to feel like the first time I ever indexed t-bars on a car that didn't have adjustable spring plates
The passenger door in progress

I need to set a rivnut for the door handle strap...this is a great tool


Panel goes on

I used leather for the release

The reupholstered door top fitted

Complete...easier than the drivers side


Passenger side with the exterior door top trim

[speedo]

I now have the car sealed up and I can roll it outside to wash it off...a long overdue shower. He has been patient...looks kind of anxious to go outside!
I'll just open the garage door

Yikes, how long have I been out here? For cryin out loud, it's almost May

Ok, shut the door and keep working. I need to finish up the mounting of the horn relay and the water pump. Bob Tilton was kind enough to send me pics of his install in "Ophelia" which is a beautiful silver SWB creation. I took some liberties and used his suggestions with a twist. I wanted to get the water pump up off the "floor", so I made a bracket to mount it next to the horn relay with easy access to the water resevoir. The beast
And the corner where it needs to go

Thin gauge steel

getting there

Shaped and painted

Trial fit

[speedo]

The horn relay and washer pump tightened up.

Early washer reservoir is a pretty basic affair

I'm done with the electronics

So I can install the strut tower brace. ChrisC and I made a few of these a while back


I need to get the front of the car up in the air to connect the brake switch to the master cylinder, and attack the plumbing. My fuel pump and filter will attach to the aluminum cross member...and I have run a return line. Hardware and "software" ready to go...

Wipers got sandblasted and painted

Cross a few more items off the list

[speedo]

This will probably irritate the purists...
But it's not like I haven't done that before. The orange enamel is in poor shape, so I carefully removed it and cleaned the badge thoughouly
I then heated it up using my halogen shop light and started adding layers of enamel

Enamel and bake...enamel and bake.
I have six coats which I will allow to cure before I clean and trim the edges

I'm down to a double column...one page punch list...closer

Sure would be nice to wash the poor guy...need to melt out first

[porschenut]

So Lars, May 6th with be the 2nd anniversary of the start of this thread...

ARE YA DONE YET????

Keystone is right around the corner!

[arrivederci]

Originally Posted by porschenut

Keystone is right around the corner!

Methinks that might be the target...