Here we go again! Zuffenhaus MS RSR project...

[eimkeith]

and



- and the front fender top was wrong, so it gets amended:





and that gets really close to final blocking/shaping/finishing work.

[eimkeith]

Previously, I neglected to post one of E. Hegg's photos during a shop event:

[m110]

Awesome
This is my favourite thread to follow
What is the engine choice with the revised and authentic project goals?

How did the factory do projects like this? Clay?

How do massive rear spacers change how the car handles? ie will it be just the most awesome looking beast or still drive well on the street or just the track or some Sicilian street with a Ferrari trailing behind.

[eimkeith]

This car will not run spacers. In fact, you can't with center locks...!

We're working on this wheel center in the background and would love to put them on this project:



like so:



That reminds me - we also protoyped a new hub design that allows the 380mm 911RS steering wheel to be mounted on the 1974-1989 911s without changing out the steering column - as seen on this build.





The hub is a 2 piece design, aluminum core for strength/safety with a delrin outer shell (the same material we used to replicate the original nylon extensions for the early four-spoke steering wheels.) The shape mimics that of the early steering column cover, which 'flowed' into the steering wheel (look at a pre-74 car if that doesn't make sense the way I described it) - for an appropriate look and wheel position.

We're currently working out the manufacturing strategy on the horn contact.

I think this hub product (will be available soon) will be just the thing for backdaters who want a factory steering wheel (or a factory-looking one .)

[eimkeith]

Ooops! I posted a photo of an RSR center lock wheel (which we are also working on for modern sizes) when I intended to post this:



- which is obviously the front side of the 917 wheel, the back side section of which I posted an engineering drawing of a moment ago.

Fat fingers today, it would seem.

[Flieger]

Have you seen Reaper 930's reproduction forged Magnesium 935 5 spoke wheels?

[eimkeith]

Regarding the engine question, here are a couple of photos of the 3.6/backdated fan FG shroud that we worked on with Series 900: (during prototyping)





This piece was shipped back to have production units pulled from it, for actual use.

[mjshira]

more nice stuff from you guys, LIKE!

[Flieger]

Seems like you guys could both benefit from working together: Teaser Vid for 935 Mag 5 Spoke Reproduction

[ktr6]

This project has been a long time coming and I really appreciate the guys at Zuffenhaus for their hard work and patience with me. I think Ive changed my mind 100 times on this project and its great to see the car take shape. Ive been in love with the original car since I was young and dreamed of owning something similar most of my life.

The goal is to have something that externally looks identical to the original 73 but is as powerful and comfortable to own as a new Porsche. Starting with an 87 allowed me to have a G50 and galvanized body. Engine will be a Zuffenhaus built 3.9 based on a 964 with PMO's. Ultimately this will be a great street/DE car.

[eimkeith]

thanks, Keith!

we're fortunate to have opportunities to build cars like this - and its always your prerogative to change your mind, its your vision, after all!

[Packy]

Have you guys ever thought of using a hand held laser scanner to scan the original? I think it generates a point cloud model and you can import it into CAD then you could CNC router a mold for for your vacuum press or whatever you use for production. Just a thought. It would make this project (and similar projects) much quicker. Here's an example of what I'm talking about... Portable 3D Laser Scanners, 3D Digitizing Systems, Handheld 3D Scanning devices - Toronto Ontario

And what trailing arms are you using? 930s?

This is like my dream job. I use to do high end custom woodworking and cabinetry. Now I'm an engineer. This is like a combo of both of those. Cool projects.

[eimkeith]

Actually Packy, our software/scanner/digitizer sub was going to use both a lazer and an arm to capture the data from our work (taking measurements/data from the original car being expressly forbidden) and for technical reasons above my pay grade, opted to use the arm exclusively.

I'm in BC for business this week, but will post pictures of that process upon my return.

The data collected is actually being used to CNC plugs for mold creation, so you are on the money as far as process goes.

Current trailing arms are Carrera, but a move to 930 might be a good idea to help with the negtive offset of the rear wheels...

[eimkeith]

As promised:

using the arm to capture the data up front




crunching 1s and 0s, I imagine


look! a fender appears where Pelican is supposed to be...

[Flieger]

That is pretty neat. Can you 'smooth' things out on that model in solidworks if you see a bulge or rough surface where you don't want, or in case you want something to be perfectly symmetrical?

[eimkeith]

Yes! In fact, during the modeling process the software guys do just that, plus mirror the bodywork for the other side (for symmetry.)

You can just see on the screen that we captured a "skirt" of data around the part that represents the contour of the fender - this extra material will aid in placement and fitment when the composites are mounted on cars down the road.

On the rear, the entire quarter is being captured and reproduced. Might even save some weight on the right end of the car when everything is said and done.

[Flieger]

OK, I see. It is like a bunch of 3D splines forming a plane, with the arm defining the inflection points. I like how Solidworks can do all those computations for you.

[eimkeith]

Originally Posted by Flieger

OK, I see. It is like a bunch of 3D splines forming a plane, with the arm defining the inflection points. I like how Solidworks can do all those computations for you.

Yes, what you said.

If I had solidworks here, I'd be dangerous (and would accomplish many things unrelated to my job )

[eimkeith]

- and the rear:

[eimkeith]

and