Just back from the pattern shop to check on our foundry patterns; got to do a little hand work on the parts while I was there to improve some of the fillets that weren't 'old' enough, and give them a more handcrafted look:

http://images.tapatalk-cdn.com/15/09...0d1763ba6d.jpg

http://images.tapatalk-cdn.com/15/09...b0dddffd02.jpg

http://images.tapatalk-cdn.com/15/09...f5b844882b.jpg

http://images.tapatalk-cdn.com/15/09...a04fdb35d6.jpg

This will be the cast reproduction RSR Spring plate bushing cover that will be used with the Rebel parts, in lieu of the machined cover that comes with the kit.

Pretty cool!


keith.

(sent from my rotary dial phone.)

Those patterns turned out great! What did you say they were making your patterns out of?

So... You going to make enough to sell? :D

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

Yep, we're going to do a short run of these for some folks. :)

keith.

(sent from my rotary dial phone.)

I love what you guys do. You're part designer, part technician, part artist, part prototyper, and all Porsche. Thats what my old job in SoCal was like, minus the Porsche part. Miss it!

Thanks, man. That's pretty much how we see it as well. :)

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

Quick update on the Spring Plate Bushing Covers; the pattern was delivered to the foundry this morning:

http://images.tapatalk-cdn.com/15/09...a2090666d0.jpg

Neat.

Also, spent the weekend on the road, brought home this vintage hot rod (affectionately known as 'voodoo' since the 70s) for some rear seat pan work:

http://images.tapatalk-cdn.com/15/09...656d4af051.jpg

Looking forward to comparing the Mary Stuart project to this one in the flesh and seeing if we've built the correct 'soul' into our project!


keith.

(sent from my rotary dial phone.)

Looking good! these are plugs to make a sand casting mold I presume? or are they using a different technique?
Hot Rod looks like fun.

Yes sir, these will be sand cast.

A quick update on our Spring plate bushing covers:

http://images.tapatalk-cdn.com/15/09...27d6e401f0.jpg

Samples in; adjustments to our pattern are being made, moving forward with enthusiasm!

http://images.tapatalk-cdn.com/15/09...f77dd31157.jpg


keith.

(sent from my rotary dial phone.)

Those look good. Really good. Decidedly not "billet" like, or obviously CNC'ed. What adjustments will you make?

Fantastic! Those look great!

nice! they look period correct.

Final piece, or will it go to the CNC to clean up surfaces?

Project is very cool!

Thanks guys! I've made some slight tweaks to the pattern (some aesthetic touches) and decided on a finer casting sand for the production pieces, and those are the only changes we'll be making.

These get machined for center bore and mounting surface only, as-cast everywhere else.

Here are the caps:

http://images.tapatalk-cdn.com/15/09...76eb2a371f.jpg

http://images.tapatalk-cdn.com/15/09...2f04a2c8a0.jpg


keith.

(sent from my rotary dial phone.)

How about that??

http://images.tapatalk-cdn.com/15/09...d37802ca47.jpg

http://images.tapatalk-cdn.com/15/09...f86582652c.jpg

http://images.tapatalk-cdn.com/15/09...41d00ee6ac.jpg


:)


keith.

(sent from my rotary dial phone.)

If you are using a CNC machine to machine the caps out of aluminum, why not do the same for the Spring plate bushing covers? They would be more expensive but better looking and stronger. Hard anodize both the same color and they would look great!

Very nice Keith, what are you planning to do about bearings? I actually have four castings of these pieces floating around since 2004? BTW, I believe my machinist took measurements of the original RSR parts I had and I was supposed to look for the correct bearings, never did. I may have to follow through with that eventually...

Great job, no less from pictures. Wow!

Here you go!

http://forums.pelicanparts.com/uploa...1442522688.jpg

http://forums.pelicanparts.com/uploa...1442522737.jpg

http://forums.pelicanparts.com/uploa...1442522757.jpg

http://forums.pelicanparts.com/uploa...1442522783.jpg

http://forums.pelicanparts.com/uploa...1442522808.jpg

http://forums.pelicanparts.com/uploa...1442522846.jpg

http://forums.pelicanparts.com/uploa...1442522884.jpg

;)

Wouldn't be historically accurate; the homologated example was a cast base/machined cap like this. (And I think the cast part looks terrific on a vintage car, honestly.)


keith.

(sent from my rotary dial phone.)

OUTSTANDING!

That is the only reference to the inside of these that I've seen! Was there also a component located in the chassis side?

I set our part up to use Rebel S Racing 's igus-based bushing kit, but could also likely configure it to use the Elephant part.

I also put an o-ringed socket under the cap to keep water out, so that is different than the original part in that respect also.

Thanks for the additional photos!


keith.

(sent from my rotary dial phone.)

Thats a fact.
Tremendous work. leading edge stuff.

(Not to thread hijack, but I just watched a "*****in Rides" episode about a '59 big American boat (can't remember the model) project that showed a trip to a foundry. They fabbed up a part for the custom grill, and had multiples cast. Really cool to see the casting process. They are in SLC, and said they were going "Down the street", but, I don't think foudrys are in every town!
Is it a common thing for you to have a part cast or is this the first? Expensive? (I'd think)

I was surprised at the amount of labor it took to set up each pour for the batch they had done.

Anyway, the surface finish looks killer.

Pretty sure you could have given CNC'd parts a very light sandblast (I use crushed glass) and they would have looked almost identicle to cast aluminum.

Anyway... looks awesome.

Looking good Keith, on to the next challenge!

Quick update: I installed a pair of these on my '72 for a 6300 mile round trip to Rennsport Reunion (including a track day), and there were no surprises with the covers.
I'll be changing the ride height (I raised the car for the trip) by accessing the bars through the end caps to re index them in the next few weeks (lots to catch up on here at the shop) and will report back as to how that goes also.


keith.

(sent from my rotary dial phone.)

And there's no thread about your journey!?!

+1 what jake said... we need the whole story & any back story there keith...!!!
P L E A S E................................ )))

I mean, 6200 miles in a 72 across the country. Something HAD to happen. Heck if NOTHING happened, it would be a story!

Yes, story please. With my 73 I can't even seem to make it out of the province without something major failing...

Ha! Thanks guys, I'll see what I can do.

In the meantime, I'm thinking about the seating for this project..


keith.

(sent from my rotary dial phone.)

Just curious, how much would am original set like these cost, how much for the new version?

Subscribed - fantastic work

Great work!

BTW, where can I get a tire down strap like that?

My 84 Rabbit had one like it.

Hi Keith,
Have you got some updates to share?

OK, just convinced Tapatalk that I do indeed have a log in, so I can post again... Phew.

I'll read through what I've missed, but to quickly update; after I got back from Rennsport I had to do two quick Celette jobs for cash flow (got an opportunity to pull a race car we built a while back!) and administrative odds and ends which cut into build time.

But we're still moving forward - I've been working on the seat issue in the background.


keith.

(sent from my rotary dial phone.)

The Mary Stuart ran a driver's side Lollipop in 1973 (!) - so that's what we're going to do also.

I've been looking at the currently available versions in the aftermarket, and in most situations there's a detail or two that I'd like to address, so we worked out a way to do that:

http://images.tapatalk-cdn.com/15/11...5389a3e79b.jpg

More on that later!

Also, one of the remaining late 911 aspects of this car is the tunnel. For the G Chassis, Porsche changed the seat mounting arrangement and omitted a sloping panel on the inside of the tunnel that was part of the seat adjustment mechanism.

There are also depressions on the sides of the tunnel behind the parking brake lever that aren't something you'd find in a '73 and aren't of any benefit to this build, so they're going away and the early sloes panels are being added.

Additionally, the RS/RSRs all seemed to run minimal, lightweight seat mounts with the race buckets, so we'll need those also.

However, the old ones that I was fortunate enough to see in photographs, and the new reproductions that are available maintain stock or very close to stock seat heights. After driving with stock seat heights for 2 weeks (including track time), I think the seat is mounted too high - certainly not low enough for my sense of comfort in a caged car - so we're doing something about that:

http://images.tapatalk-cdn.com/15/11...c900e220c0.jpg
(Front mount/cross rail pictured)

We should be able to drop the seat 30mm and keep the lightweight historic seat mount appearance thusly.

AND, since this is a dual-purpose car, open megaphones aren't going to work, although they'd be accurate. We need to provide a modicum of heat and defrost, and avoid bleeding eardrums, so I'm working on that also. I'm thinking the RSR rally muffler (with removable caps) is going to be the way to go here - correct outlet positioning, correct era part, etc. More on that front as it develops!





keith.

(sent from my rotary dial phone.)

I did actually sit down and write a short essay about my trip - and our local PCA is running it in the club newsletter in 3 installments, so I can only share the first part at the moment; but if you want to check that out, I've put it up on our blog here:

http://www.eurowerks.us/WordPress/

Hopefully it is 1/100th as entertaining as the trip was!


keith.

(sent from my rotary dial phone.)

Hi Keith

Re the muffler you might want to look at Mike Moore's amazing martini build over on DDK (if you've got a spare day!)

DDK - Die Deutschen Klassiker • View topic - My new project.........

He did a separate thread about the muffler

DDK - Die Deutschen Klassiker • View topic - RSR exhaust box

I know he had some extra mufflers manufactured but I think they may have all been sold

this allowed him to adjust the route of the exhaust gasses by means of a hidden flap and small bolt. I was thinking the same thing could be achieved with a servo - thereby allowing you to change the exhaust from within the cabin.

Cheers

Sladey

Thanks! Will spend some time with that.


keith.

(sent from my rotary dial phone.)

If you haven't seen it before it's an amazing build and takes OCD to another level

I think I just answered my own question. Aparently the washer bottle is held by that strap when in its normal location as a washer bottle. I didn't know.

I guess thats one of the pitfalls of buying a 73 race car in boxes :-)

Sory for the interruption. Carry on ;)