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

[tops911]

thanks

[tmsautoart]

Any updates?

[Youngbp04]

I am in for updates as well

...

(First Post!)

[eimkeith]

Hey guys, thanks for posting - the subscription updates made me aware that it's been a while since I've updated the thread.

I'll be posting some pictures of the final carbon fiber parts shortly (after I photograph them!)

There are some preliminary shots on the Zuffenhaus blog in the interim, for those who can't wait.


keith.

(sent from my rotary dial phone.)

[Unobtanium-inc]

Originally Posted by eimkeith

It's good to know I'm not the only guy with a A1 GTI stuffed into the shop someplace.

[silverc4s]

Sub'd

[lateapex911]

Originally Posted by eimkeith

Hey guys. We can't seem to behave like a normal shop around here.

I thought you might be interested in a current project:
(this is why you should never leave your car unattended at zuffenhaus)

a client brought us his really clean '87 Carrera to get a little work - rollbar install, sunroof delete, and driprail removal.


- then, while we are in there, why not a 935 mirror conversion, and FULL rollcage, for SERIOUS trackwork (and rigidity)

Funny, I've missed this for the entire thread. Old news now, LOL. But I see you've done a drip rail delete. Do you grind away alternate sections then (It looks like mig) weld the gap? Hop skipping along? Do you back the gap with a spline of metal? (I'm guessing not) and...is there any loss in chassis/tub stiffness?
Do you then grind the welds (A assume they are linked together continuously) and fill any pinholes with filler?

Thanks, always curious about the process.

[eimkeith]

OK, here we go!

We've gotten all of the panels from our carbon fiber guy. The panels are outstanding - consistent thickness, beautiful surface, I could go on....

Here is the 911 with the mocked-up Mary Stuart quarter panel/wing and the resulting carbon panels, ready for fitment:

[eimkeith]

And, the moment I've been waiting for -






This was actually more difficult than I'd imagined it would be - physically, I mean - as it turned out to be suprisingly well constructed!

A lot of time, effort, and capital was swept off of the floor and ended up in the bin.

[eimkeith]

And, the photos you guys have been waiting for:

This is the passenger rear quarter removed, with a flange in place for bonding the carbon panel to. This flange is generous at the moment, and will be trimmed down for final attachment.





You can see how much of the tail light housing we leave when we bond composite panels on - this way the fitment is as-produced by Porsche.

The initial test fit went well. It was a nail-biter for me, personally - there was no end to the amount of jigging, measuring, checking, etc. that was used for contour verification before committing to the final shape of the positive plugs that the molds we made from - but I couldn't actually exhale until a panel actually FIT on the 911.

- it does fit on the 911:








- and it is symmetrical to the mock-up work (seen on the driver's side in this picture.)



The passenger side is being mounted first, so as to allow the mock-up work to serve as final position reference/check.


I appreciate everyone's patience with the updates - we wear many hats nowadays (short on staff) and it takes considerable time to photograph/upload/update during other business activities.

I'll work on keeping the progress shots more current in this and other threads, bear with me.

[jpnovak]

Well Done Keith!

[OffCamber00]

Great job Keith and Aaron. Glad to see this finally coming to fruition for you guys!!

[redturbo911]

Amazing job. Thanks for bringing us along.

[jjwood]

Excellent job guys. Can hardly wait to see the finished project. Just curious -- do you plan to market the flares?

[eimkeith]

Originally Posted by jjwood

Just curious -- do you plan to market the flares?

Yes Sir!

[mamut]

Excellent money pit!!!!!!!!!!!!!!

[totle]

Thanks for the update:-) great :-)

[jm993rs]

[lateapex911]

Originally Posted by eimkeith

And, the photos you guys have been waiting for:

This is the passenger rear quarter removed, with a flange in place for bonding the carbon panel to. This flange is generous at the moment, and will be trimmed down for final attachment.



.

Unf! That chassis is soooo clean. I love a silver chassis,
Oh, and the quarters are pretty neat too.
Actually, thats top notch prototype work. Not surprised that you will be producing them!

[juicersr]

Congrats Keith on a really nicely done job on a unique piece of bodywork. U guys really did it justice.