Ok, I've gotten the roof stripped, hammered out some dents (while the pillars and inner roof structure was still attached to avoid distorting anything) , cut out the section we'll be using, and took the opportunity to roll out some hammer marks and smooth the dent removal work while I have edge access to wheel the panel.

Stripping the donor roof:
http://images.tapatalk-cdn.com/15/07...9c2df79203.jpg

Drilling spot welds along top of both windshields and marking a cut line above the drip rail:
http://images.tapatalk-cdn.com/15/07...f9c4665325.jpg

Donor panel cut from roof, and unused portions:
http://images.tapatalk-cdn.com/15/07...1f14b672b4.jpg

http://images.tapatalk-cdn.com/15/07...bd423d6762.jpg

http://images.tapatalk-cdn.com/15/07...5ae26dbd30.jpg

Smoothing the dent repair work:
http://images.tapatalk-cdn.com/15/07...be584e72de.jpg

And the panel ready to go.
http://images.tapatalk-cdn.com/15/07...740a8573f2.jpg

In answer to the previous question, we don't cut through any structural areas, instead we're just replacing the skin within the drip rails.

We'll be welding down the sides, on the contoured face to help mitigate panel distortion, and our weld won't be visible from the cabin. We'll plug weld the drilled spot weld holes on the windshield flanges, like the factory attachment there.

No structural impact!

Here's the project car, roof marked for cutting (this cut line is higher than the donor panel and will be the preliminary cut.). The roof will be positioned over the hole we make, supported by the flange we leave on the sides.

http://images.tapatalk-cdn.com/15/07...cf145b3893.jpg

I'll pick this back up on Tuesday; I've got a printer failure to deal with and an electrical circuit to upgrade in the interim (always something!)


keith.

(sent from my rotary dial phone.)

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

Snuck in some work on the roof today.

Shave and a haircut:

http://images.tapatalk-cdn.com/15/07...a488148eca.jpg

http://images.tapatalk-cdn.com/15/07...ca29db69f7.jpg


Removing the sunroof drain tubes while I have the opportunity:

http://images.tapatalk-cdn.com/15/07...1d260d6904.jpg

http://images.tapatalk-cdn.com/15/07...93d848773f.jpg


Positioning the donor to start trimming it in:

http://images.tapatalk-cdn.com/15/07...8300fbfee4.jpg


Also, had a chat with Clint @ Rebel Racing about our RSR Spring Plate covers for his Spring Plate Bushing kits, and he's into the idea, so I'm looking in to the feasibility of some short run production on them.

Here's the Spring Plate cover modeled up for casting:

http://images.tapatalk-cdn.com/15/07...552d80e87d.jpg


Moving right along!


keith.

(sent from my rotary dial phone.)

Awesome Thanks!

GREAT WORK. So much that was done its mind blowing.

Thanks guys, we're closing in on this one.

Tub Prep
 

Keith,
Just wondering if this tub was baked and e-coated. Sorry if it was stated earlier, haven't had time to read through the whole thread. Awesome work, can't wait to see it finished.

This one was baked off and powder coated, but not e-coated; the thinking was that Porsche had done a thorough job with their galvanizing (which turned out to no be the case; the rockers need rust repair, which is coming up next.)

I suppose that rust is a thing with all of these cars - they are getting on in years, as it were.

Snuck in a couple of hours to get started on the roof before I was chained to the desk this morning :

http://images.tapatalk-cdn.com/15/07...2b25ef808d.jpg

Windshield fit is good.


keith.

(sent from my rotary dial phone.)

Stunning work.

Thanks Antonov! - appreciated!

Not much to show yet, but I'm on day 3 of working out the shifter (needed a break from welding.)

http://images.tapatalk-cdn.com/15/07...1b7feed856.jpg

This is the general idea:
(First study from Saturday)

http://images.tapatalk-cdn.com/15/07...89985494bd.jpg

I think I can make this happen with 3 parts...? We'll see.


keith.

(sent from my rotary dial phone.)

You guys with this kind of fabricating skill amaze me.

Thanks!

But I'm really just modeling and printing at the moment (using different 'muscles' I suppose!)


keith.

(sent from my rotary dial phone.)

Where did you find the jig to align the top? Wonder if one could be rented from someone in the SF Bay Area.

By the way, your project is coming along very nicely. You are very brave!

I must have forgotten, eimkeith...why did you have to replace the roof again? Or was it just a sunroof delete? don't people just weld that up?

a very nice way to start my day = see a new post from keith on this or ANY projects he & his team are working on...
a quick q: are u going to cast the spring plate cover...?
and a probably dumb q: do u have to make a left & right side version or will what u have been showing us work on both sides of car...?
carry on...))

It's covered on page 23.

Keith, allways nice to see your updates, keep up the good work!
Love your 3D printer BTW, maybe if I'm nice this year I'll get one for Christmas :D

We originally deleted the sunroof on this car by welding in the sunroof panel; it was in fact, the last one we did using that approach. That would have been fine, but when the decision was made to go full-on Mary Stuart R7 for the project, we had to have a clear roof, cabin-side (the Mary Stuart did not run a headliner.) So, off comes the welded-in roof, on goes an original sunroof-delete roof.

(Saved ANOTHER 5 pounds over the welded-in roof, btw.) :)

Thanks! Very much appreciated!

Yes, we're costing out the spring plate cover for production - luckily it is symmetrical, so we'll only need one mold for casting, so there's that. I'm getting machining quotes on the cover and the end cap to determine where this will come in, cost-wise for the general market.

I'm pretty pleased with it so far; I'll likely put a set on my 911 as well!

Thank you.

If you do get a printer, you should give Fusion3 a look - they're a NC start-up (we have their 56th printer) that offers a large print envelope (12x12x12inches) and have been killing it in the customer support department for us; anytime I break down (and I run our printer like an employee on probation) they have the parts I need in my hand the next day. I expect they'll get even better with time.