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

[ktr6]

I appreciate all of the interest in my 911 but this car has been sold. It will be staying in Charlotte as the new owner has decided to have the project completed at Zuffenhaus in the coming months. I look forward to seeing this build completed and appreciate all of the hard work from Keith and Aaron.

[Facey]

those are great looking flares.

[Ferrino]

Amazing build - would love to see what became of it.

Do you happen to have any pics of closing up the sunroof using the existing sunroof panel? Did you just fabricate some thin strips to pack out the gap previously taken up by the seals?

[nameisbauer]

I cannot comment on what they did, but I removed the inner sub-roof when doing the sunroof delete. So, If I understand your question correctly, there is no gap to fill. basically you are back to a flat roof. And removed a ton of weight, up high.

[Ferrino]

What did you use to "plug" the hole where the stock sliding sunroof panel used to be? I've seen various methods: fiberglass plugs that are bonded in, metal plugs that have a "step/flange" pressed in and either bonded or spot-welded in, then people who re-use the sliding sunroof panel. For the latter case, the panel must be smaller than the hole because of the presence of the gasket/seal. From what I've read though, bonding is the best method, to avoid warping with welding.

Originally Posted by nameisbauer

I cannot comment on what they did, but I removed the inner sub-roof when doing the sunroof delete. So, If I understand your question correctly, there is no gap to fill. basically you are back to a flat roof. And removed a ton of weight, up high.

[nameisbauer]

I had an entire roof clip to use, but my body man decided to just weld the original sunroof panel in. After the fact, he did admit it was a lot of work, but it looks perfect.

[carslutt]

wow, panels turned out great!

[eimkeith]

Originally Posted by Ferrino

Do you happen to have any pics of closing up the sunroof using the existing sunroof panel? Did you just fabricate some thin strips to pack out the gap previously taken up by the seals?

Sorry I haven't been active on Pelican for some time; did not mean to ignore any questions.

We closed this panel as you've described, and I believe it is the last one we did with this method.

We have been replacing roof skins since - less risk of distortion, better contours, less time investment: better all around if you have access to a donor roof, in our experience.

[eimkeith]

Originally Posted by nameisbauer

I had an entire roof clip to use, but my body man decided to just weld the original sunroof panel in. After the fact, he did admit it was a lot of work, but it looks perfect.

want to sell that clip?

[eimkeith]

Originally Posted by carslutt

wow, panels turned out great!

Thank you.

Since I last posted on this thread, I sculpted the front and rear bumpers (again, left sides only) and had the contours captured digitally with a ROMER arm.

However, in the time since the last post, I've taken classes after hours and moved the solid modeling in-house, so as to have better detail control.

I have some photos of the bumper mock-ups at the office, but here is a shot of the front in the digital environment (it goes to CNC when I finalize this file):

[eimkeith]

and here is a quick one of the rear bumper foam carving in progress (again, the left side is the finalized contour):

[al lkosmal]

Keith,
Mad skiills...what cad program are you using?

regards,
al

[eimkeith]

Reviewing the thread, I see we left off updating after the arrival of the Carbon panels.

Since that time, the project kicked up a notch (more than a notch, actually) toward historic appropriateness if not accuracy(how accurate can a back-date be?)

After a query from the owner as to the appropriateness of ITBs over PMOs for a Mary Stuart tribute turned into a multi-day conversation about MFI (one of my favorite things), this project shifted into high gear and the gloves came off.

IN ADDITION to ditching the PMOs and moving to mechanical injection, the build plan was revised for the final time; historic visual accuracy is now the objective.

I researched Pelican and the rest of the internet to locate 3.6L (thie engine is a 3.9 built upon a 3.6 964 case) MFI injector blocks, and of the scant few examples I found, Len Cummings we the most promising, but no longer available. So with his blessing, we set out to reproduce them, but ended up designing our own. MFI for Mary.

We designed and prototyped in-house (printed) to prove out the part:









our finalized design (revision 5) kept the height of the throttle bodies as low as possible for the pump to throttle relationship of the linkage, and looks like this installed (ignore the high butterflies, they are being used for mock-up only):

[eimkeith]

Now that we're satisfied that the mounting of the throttle bodies to the 3.6L heads and correlation to the pump is sorted, we're working with Aaron Burnham and Kurt Donohoe (Burnham Performance and ************, respectively) to design a 12 plug ignition system for this project.

After trial-fitting several distributors to check for clearance vs. the 3.6 case, we've opted for a 3.0 distributor as the basis for the 12 point Aaron is providing.


(pictures of this to come.)

Kurt is designing our dual CDI system currently.

[eimkeith]

We've also put effort into other key visual areas of the build; I'll post background as to the decisions that were made and the paths chosen after I get this tub to the mold shop for the final casting of the fenders (first of the month)

- until then, I'm every day drilling spot welds, cutting & welding to bring this car to the stated objectives (accuracy/visual appropriateness)

Significant additional work to the chassis; my kind of build.

[eimkeith]

Originally Posted by al lkosmal

Keith,
Mad skiills...what cad program are you using?

regards,
al

Hi Al. Inventor.

Not nearly as proficient as I need to be, but it's been an important part of our business, and allows us to do more in-house.

[eimkeith]

So this is how the 3.9L sits at the moment, incorrect shroud, and using high butterflies to mock up the MFI system:




- and this is how it WILL look when we are finished:



Our 3.6L Injector Blocks are allowing us to us a correct shroud, so we've moved our custom 3.6 conversion shroud to another engine project (with the 50mm PMOs - this engine is available if anyone needs a practical 3.6 for their backdate project )

The Slide Valves and engine fiberglass are being supplied by TwinSpark in the Netherlands (who carry our products for the european market as well.)

TwinSpark is also supplying the RSR Pedal Cluster (more on that later.)

[scootermcrad]

Man! I really need to take a day off and come by the shop. Nice work! It's really looking great!

When going from CAD (SolidWorks??) to prototype on the bumper stuff, are you RP'ing the bumper in sections, or did you actually have a mold made and lay it up?

[eimkeith]

Originally Posted by scootermcrad

Man! I really need to take a day off and come by the shop. Nice work! It's really looking great!

When going from CAD (SolidWorks??) to prototype on the bumper stuff, are you RP'ing the bumper in sections, or did you actually have a mold made and lay it up?

Thank you.

We go from solid model to a full scale machined-foam part, to use as a positive plug for mold creation. This plug gets touched up by hand using the sculpted part as reference, then handed off to the mold-maker for surfacing. He then creates the mold from it to produce the final part.

Here's an example of this process with the rear quarters:
machined plug before touch up
and the plug during machining

For the bumpers, we'll print critical contour sections in 1/2 scale and a 1/8 scale complete bumper to check proportion and shape before committing to full scale foam. (Hopefully this will reduce the 'touch up' time after machining.)

We learn as we go!

[scootermcrad]

Originally Posted by eimkeith

Thank you.

We go from solid model to a full scale machined-foam part, to use as a positive plug for mold creation. This plug gets touched up by hand using the sculpted part as reference, then handed off to the mold-maker for surfacing. He then creates the mold from it to produce the final part.

Here's an example of this process with the rear quarters:
machined plug before touch up
and the plug during machining

For the bumpers, we'll print critical contour sections in 1/2 scale and a 1/8 scale complete bumper to check proportion and shape before committing to full scale foam. (Hopefully this will reduce the 'touch up' time after machining.)

We learn as we go!

WOW! Okay. That makes complete sense. Very cool! Is that foam being cut in-house on your own machines? Those CNC gantry mills are very cool! Possibilities seem endless for what can be done.