I couldn't find one to buy or rent! :(

(but I'm in the market if you come across any.)

More work on the shifter today (need to get back on welding, but it's hard for me to transition back & forth in the proper frame of mind, so I'm seeing the design work through)

http://images.tapatalk-cdn.com/15/07...3625c28ff8.jpg

http://images.tapatalk-cdn.com/15/07...3a7f94f34a.jpg

There's enough going on in the wacko G50 shift assembly as it is; much respect for Wevo and JWest for tackling this for such a small number of cars.

I'm making it worse for myself by putting a 915 shift tower on top - I've got to limit shift lever movement accordingly to work through the vertical 'tube', but still get the travel and angles needed in the tunnel.

The photos above are my 3rd version, 2nd revision (shown without the 915 tower installed.)

I'm printing revision 3 this evening. ;)

Closing in on it.


keith.

(sent from my rotary dial phone.)

Ok, revision 4 is a winner. Full fore/aft travel, ample degrees of rotation on the gear selector shaft.

http://images.tapatalk-cdn.com/15/07...246ae2b822.jpg

This is what it will look like with the 915 shift tower installed over it:

http://images.tapatalk-cdn.com/15/07...b88aa7e8b6.jpg

(Imagine a 915 shift lever installed, with boot.)


keith.

(sent from my rotary dial phone.)

I am so envious of you, Keith. To be able to spend your days doing design and fabrication on these cars .... and get paid to do it.... nice!

I know you must have bad days from time to time. But I sure it beats the hell outta my desk job.

Keep it up. I'm living vicariously through your posts.

Lol, glad you're enjoying the thread.


keith.

(sent from my rotary dial phone.)

Quick Tuesday morning update:

I couldn't locate a good original RSR transmission cooler (the end of the road for the hard lines on the driver's side of the Mary Stuart), so I got started on converting an RS-style trombone cooler.

Here's the cooler and the reference photo (photo of '74 RSR):

http://images.tapatalk-cdn.com/15/07...5a2b3aa527.jpg



Right-hand brackets/tabs de-brazed.

http://images.tapatalk-cdn.com/15/07...0d3c8be3fb.jpg


So far, so good!


keith.

(sent from my rotary dial phone.)

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

Back on the roof welding (1/2 completed)

http://images.tapatalk-cdn.com/15/07...683d097f9a.jpg

http://images.tapatalk-cdn.com/15/07...7e9f8deabc.jpg

keith.

(sent from my rotary dial phone.)

Cleaning up some rocker rust this morning.

http://images.tapatalk-cdn.com/15/07...589cd25c20.jpg

A little disappointed with the patch panels available, though:

http://images.tapatalk-cdn.com/15/07...d4cd29b223.jpg


keith.

(sent from my rotary dial phone.)

Would you mind posting any pictures you had of the sunroof weld up job you performed?

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

The previous time (welded in sunroof panel) or this time around (replaced roof skin)?

I don't have photos of the first time it was done (I wasn't the primary on this project until the carbon bodywork phase) - but I don't recommend the weld-the-sunroof-panel approach.



keith.

(sent from my rotary dial phone.)

Almost wrapped the driver's side rocker repair today (misplaced the lower quarter panel face piece I removed several weeks ago, can't finish this until I find that damn thing!)

Here's some pictures of today's work.

http://images.tapatalk-cdn.com/15/07...e694d60964.jpg

http://images.tapatalk-cdn.com/15/07...cd2bb70bf1.jpg

http://images.tapatalk-cdn.com/15/07...1b6cf5fb70.jpg

http://images.tapatalk-cdn.com/15/07...1d81aad510.jpg

http://images.tapatalk-cdn.com/15/07...96ef716960.jpg

http://images.tapatalk-cdn.com/15/07...5e7bcfe1af.jpg
(Had to slit this piece to narrow it to fit)

http://images.tapatalk-cdn.com/15/07...827464dc76.jpg

http://images.tapatalk-cdn.com/15/07...a68a4e255d.jpg

http://images.tapatalk-cdn.com/15/07...fdfc27dfb3.jpg

Now to find that missing piece.. >:(


keith.

(sent from my rotary dial phone.)

Hey keith,
yeah , was wanting to see the first plug up.. when you welded a plug in the sunroof... not so much the reskin... thanks.

sorry; I don't have any photos of that previous work.

I can tell you that filler strips were used, and a lot of forming is needed to control distortion - that method requires welding in the middle of a relatively flat plane, no natural curvature to resist drawing of the heat affected zone (plus there are two closely spaced parallel lines of weld around the sunroof - making the draw worse.)

hope that helps in some fashion?

Worked on the passenger side rocker today (funny how the one with less rust took longer; didn't quite finish it)

http://images.tapatalk-cdn.com/15/07...25d97e32e8.jpg

Down to the good stuff
http://images.tapatalk-cdn.com/15/07...3850ffd733.jpg

Fitting the patch
http://images.tapatalk-cdn.com/15/07...14a1cb8fec.jpg

http://images.tapatalk-cdn.com/15/07...9a68ea513c.jpg

http://images.tapatalk-cdn.com/15/07...c6342d7d5e.jpg


Fitting the top layer
http://images.tapatalk-cdn.com/15/07...1bd176c0b6.jpg

Didn't get a shot of that welded in, but finished the day with welds that need to be ground & finished, then primed.


keith.

(sent from my rotary dial phone.)

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

Working on the 930 trailing arm mount conversion today, but never posted the finished rocker repair on the passenger side, so here it is:

http://images.tapatalk-cdn.com/15/08...11aad4c7b0.jpg

OK, trailing arm mounts.

You'll recall that we're using 930 trailing arms (wider track, massive bearings, etc.) on this build, so we need to modify the pickup points on the chassis.

I modeled up a conversion that visually references the RSR solution in 1973:

http://forums.pelicanparts.com/uploa...1429797196.jpg


I started making the pieces today, using templates I'd printed out to mark the material for drilling & trimming.

http://images.tapatalk-cdn.com/15/08...6a8974ab3d.jpg

Make a pilot drill jig
http://images.tapatalk-cdn.com/15/08...642fc67935.jpg

http://images.tapatalk-cdn.com/15/08...8baf71d9fd.jpg

http://images.tapatalk-cdn.com/15/08...d6d79b60d1.jpg

Similar tolerances to original trailing arm bolt holes.


Here's the fitting work on another G50 housing:

http://images.tapatalk-cdn.com/15/08...df24b2305f.jpg

http://images.tapatalk-cdn.com/15/08...48532dd484.jpg


keith.

(sent from my rotary dial phone.)

My (symmetrical) installation tool doesn't line up with the transaxle mount on one side of the mock up torsion bar housing, surprisingly.

http://images.tapatalk-cdn.com/15/08...ef87e7a374.jpg

I'm assuming there are deviations during manufacturing so I'm modifying the file and printing another install tool, this time with slotted holes at the transaxle mount.

I've also concluded that I will in fact need to cut welding access holes in the rear seat pan (thought I could avoid that) to install these mounts properly.

Such is life!


keith.

(sent from my rotary dial phone.)

Alright, back at it with new install tool (12 hr print)

http://images.tapatalk-cdn.com/15/08...745c00cf42.jpg


Hard to see here, but ample clearance for locating hole now.

http://images.tapatalk-cdn.com/15/08...cd00ce5663.jpg


keith.

(sent from my rotary dial phone.)

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

Access!

http://images.tapatalk-cdn.com/15/08...582fb715c2.jpg


Fitting to the cast portion of the torsion bar housing:

http://images.tapatalk-cdn.com/15/08...021778e03e.jpg

http://images.tapatalk-cdn.com/15/08...539fab35b6.jpg

More work needed here for proper fit.

keith.

(sent from my rotary dial phone.)

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

And tacked in.

http://images.tapatalk-cdn.com/15/08...a8e5ada1fb.jpg

Now to mock assemble the suspension and set up the car to verify alignment before finish welding and adding the bracing.


keith.

(sent from my rotary dial phone.)

Fascinating, superb and overall uber-cool design and workmanship. John in CT

Ha! Thanks John.


keith.

(sent from my rotary dial phone.)

Now THAT'S some bad ass work, right there! Nice job, Keith! I have got to try and get over there, next week.

I have to replace a Torsion bar tube on my '70. Maybe I can pick your brain on this topic...

Sure thing.




keith.

(sent from my rotary dial phone.)

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

Working on prepping the suspension today; hoping to assemble to near final setup at this point to make final car assembly more efficient later.

The objective is to put the suspension on the car, install the engine and transaxle, rough in the ride height and corner weights and do an alignment prior to finishing the trailing arm mounts to verify the design work. Then it will come back apart and go ont the rotisserie for final metalwork.

Here's is what is being replaced in the rear:

http://images.tapatalk-cdn.com/15/08...84e7fb2218.jpg

We love this Elephant/Fox combination but it isn't visually compatible with the project goals.


Yesterday I soda blasted and cleaned the 930 arms, today Ido a final clean and begin assembly.

http://images.tapatalk-cdn.com/15/08...c81f952ab0.jpg


keith.

(sent from my rotary dial phone.)

Reworked my RSR Spring Plate Bushing Cover over the weekend after meeting with the pattern maker (of course he wanted more draft.). ;)

Here's where the solid model stands now:

http://images.tapatalk-cdn.com/15/08...603d40a2dc.jpg

I'm printing it to double-check my critical dimensions and general proportions, then it's off to the pattern-maker & foundry.

(If I can get these turned around in time, I'll take one with me to Rennsport in case any of you want to see it in person.)




keith.

(sent from my rotary dial phone.)

I've gotta' bump this up to say how incredible this car is. I got a chance to see this thing in person yesterday and the details and thought put into this build are above and beyond!

Well done! My hat's off to ZUF!

Thanks!


keith.

(sent from my rotary dial phone.)

Have I mentioned the '73 RSR transmission oil cooler in the left front fender (wing?).

The original looks very much like the RS trombone oil cooler with the mounting tabs relocated.

Did I forget to mention my first attempt with modifying a new Porsche cooler? It went well at first; I successfully removed the brazed steel tabs (higher temperatures needed for this) from the brass cooler, then fumbled the re-brazing:

http://images.tapatalk-cdn.com/15/08...ebe3de0896.jpg

Ouch.

I ordered another cooler from Porsche and after wringing my hands for a few days, managed to screw my courage to the sticking place and go at it again this morning.

I cautiously removed the tabs from the replacement cooler as before

http://images.tapatalk-cdn.com/15/08...447722dbf9.jpg

http://images.tapatalk-cdn.com/15/08...52745edb62.jpg

And proceeded to braze the steel tab back on the other tube:

http://images.tapatalk-cdn.com/15/08...e6282d1d0b.jpg

Success!

http://images.tapatalk-cdn.com/15/08...19a745891d.jpg

That was a nail-biter. I'd like to think I was a better brazer in college, but that might be romanticizing the good old days...


keith.

(sent from my rotary dial phone.)

I tested the cooler for leaks in a bucket of water, using the 2 plastic caps that shipped with the cooler, poking a hole in one for pressurizing with compressed air. Aaron (the other half of the Zuf Army) and I were peering down into the bucket looking for bubbles when the pressure in the cooler finally overwhelmed the other shipping cap and lodged it into our ceiling (23 foot tall ceiling) - so I'm considering that as passing the pressure test.


keith.

(sent from my rotary dial phone.)

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

On to mounting. This cooler has to fit against the contoured section of the G Chassis trunk wall that accommodated the battery, whilst also clearing the fender/bumper mounting flange, the turn signal assembly, the curve of the bumper, and the headlight bucket.

http://images.tapatalk-cdn.com/15/08...392dd5b2a4.jpg

http://images.tapatalk-cdn.com/15/08...d7123c6c89.jpg

http://images.tapatalk-cdn.com/15/08...5d35923ec1.jpg

The preliminary position was marked, the brazed tab heated and re-shaped a bit, and the fender was pulled for mounting.

http://images.tapatalk-cdn.com/15/08...daae2de843.jpg

http://images.tapatalk-cdn.com/15/08...1ba9f2640a.jpg

http://images.tapatalk-cdn.com/15/08...f8e25728d4.jpg

http://images.tapatalk-cdn.com/15/08...0b84d37089.jpg

That'll do nicely.


keith.

(sent from my rotary dial phone.)

Preparing suspension this morning (just got steel parts back from coat, installing with a combination of Elephant and Rebel bushings.)

http://images.tapatalk-cdn.com/15/09...331baa926a.jpg

http://images.tapatalk-cdn.com/15/09...d0e3ffb1d0.jpg


keith.

(sent from my rotary dial phone.)

Keith as usual nothing but perfection. One thing I'm curious about is why the trombone over a radiator style?

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

Historical accuracy. I'll dig up a photo from a '74 RSR that I used for reference (which is a year off, but I believe is correct for this project.)

And thanks for the compliment; perfect may be a stretch, but I appreciate it!

keith.

(sent from my rotary dial phone.)

subs

So this has happened:

http://images.tapatalk-cdn.com/15/09...f922a69f70.jpg

:Beer:


keith.

(sent from my rotary dial phone.)

Woof. Some nice looking parts there.
Love this thread.

Back on suspension fitting this morning.

http://images.tapatalk-cdn.com/15/09...c018a78723.jpg

Some clearancing needed for the Rebel parts.

http://images.tapatalk-cdn.com/15/09...e5fa31fec4.jpg

End result is fantastic.

http://images.tapatalk-cdn.com/15/09...6c8078a024.jpg


keith.

(sent from my rotary dial phone.)

Keith, is that black zinc or black oxide or powder coat?

On the suspension stuff? None of those. ;)




keith.

(sent from my rotary dial phone.)

black nickel?

do tell!