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

[eimkeith]

Holy Moly, the Amazon reviews on that are off the charts. Will make this change immediately!

[jhelgesen]

I got mine from Mcmaster and the adhesive sheet off amazon.

Haven't had to use an glue since i switched.

[eimkeith]

sounds like a miracle - thanks for the heads-up!

[PMNorris]

Fantastic project. Subscribed

[eimkeith]

Finished the revised jig pilot hole alignment tool and put it to use this morning; it is dimensionally the same as the last one, but has a larger center bore (so I can pilot the hole saw with it now!)



Worked just fine, kept things perpendicular.











Nail-biter!



keith.

(sent from my rotary dial phone.)

[eimkeith]

And #2!





Milestone!


keith.

(sent from my rotary dial phone.)

[Ferrino]

That hole jig is giving me a geek-on!

[Craig_D]

Originally Posted by Ferrino

That hole jig is giving me a geek-on!

LOL! Indeed! Very nice!

[eimkeith]

getting some weird Tapatalk errors suddenly, which is crimping my posting convenience... So a short one from the desktop.

Was able to get both front flares bonded on this afternoon - they're permanent now.



In the morning I'll remove the fenders, get the hood out of the way, and get back to finishing up the trunk (finally.)

And after this project, I'm going to try to avoid working with carbon fiber - it gives me an incredible rash, must be allergic to something in it, somehow.

Proper old school fiberglass for me.

[KTL]

So you drilled up from the bottom to establish the pilot hole in the hood, then drilled down with the hole saw into the pilot hole in the 3D printed jig? Nice!

I can't believe you didn't design a drill bushing into the jig. You guys at Zuffenhaus are total hacks..........

[Tobyb]

This is some really amazing craftsmanship, well done. I love it that you still have the motivation to push on as hard as you are, even after all this time.
Do you know how many hours you have put into it?
Toby

[eimkeith]

Originally Posted by KTL

So you drilled up from the bottom to establish the pilot hole in the hood, then drilled down with the hole saw into the pilot hole in the 3D printed jig? Nice!

I can't believe you didn't design a drill bushing into the jig. You guys at Zuffenhaus are total hacks..........

yeah, pretty much - these are limited use tools at best, and I'm substituting silicone spray for the bushing

along those lines, here's the strut brace pilot hole locators I'm printing for tomorrow:



I'm hoping those work as well as the hood fill stuff did; the strut tower brace assembly/installation has a lot of things going on, plane and axis-wise, need some extra hands, so to speak.

[eimkeith]

Originally Posted by Tobyb

This is some really amazing craftsmanship, well done. I love it that you still have the motivation to push on as hard as you are, even after all this time.
Do you know how many hours you have put into it?
Toby

Thanks Toby!

I have no idea about the total build hours - I've only tracked the hours I've personally put in to this project.

Aside from the flares & bumpers part of the project (which is being handled separately from the car construction), I can tell you that since April 11 I've put in 188 hours on the physical chassis work, plus the design & modeling time of these printed bits, and about 10 hours of research. March and the first half of April was all about the custom stuff that had to be designed for use on this build.

I was really hoping to get this thing to paint by the end of the week so I could take Memorial Day off!

Still big areas to resolve, though - and I'm still in the trunk :/

[eimkeith]

I spent some time trimming the strut brace uprights to fit the contours of the strut towers this morning, then checked the printed parts.

Looks like they're going to work.





In theory, these should allow me to more of less install the strut tower brace, then correctly drill the through holes for the bolt sleeves.

[eimkeith]

Originally Posted by 78-911SC

Keith thanks. Just a couple more questions if you don't mind. What size rivet? Do you leave it in after assemble? If no what do you do about the hole if nothing do you touch them up? I have built my own plane so I have different sizes on hand. If you do remove the rivet than instead of rivets do you think clecos would work?

Here is how I'm making reference/alignment pins/holes with the stem of 1/8 inch rivets (5/64 hole, IIRC.)







and so on.

[eimkeith]

so the strut brace is positioned and tacked in (the pilot/locating tools worked great):





and here's where I'm leaving off for today; in the process of locating and determining mounting arrangements for the dual RSR fuel pumps and the brake fluid reservoirs.





it's starting feel like things are coming together a bit!

[proffighter]

I am glad not beeing the only nuts DIY geek here! Very nice work

[eimkeith]

Originally Posted by proffighter

I am glad not beeing the only nuts DIY geek here! Very nice work

Ha, thanks. Shop here, though - so you're still on your own.

[eimkeith]

Back up on Tapatalk it seems!

Putting in hours on the backdated trunk wall/battery box delete today.

This is the lower flange that the trunk wall will sit against:



Filling a hole:



And here is the block off plate for the battery box (actually the trunk wall):



More on this to come.


keith.

(sent from my rotary dial phone.)

[eimkeith]

And some last minute stuff before I go home:

Put in the weld nut/receivers for the fuel pump mounts - wanted to get them installed before the bulkhead panel is welded in.





(Yes, I still need to strip the bottom side of this panel)

Here's how it looks mocked up:



So far so good!


keith.

(sent from my rotary dial phone.)