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

[LJ851]

How is this project coming along?

[eimkeith]

wow - I owe this thread an update!

let me go find the photographs since my last post..

[kenikh]

I saved you the trouble:




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[gestalt1]

Nice!

[eimkeith]

That's correct; complete change of direction since December.



so here's where we left off, thread-wise, as best I can tell:

[eimkeith]

From there the 911 went back on the alignment rack with the drivetrain installed to confirm chassis setup.

I didn't like the range of camber adjustment or the position of the wheels in the wheel wells on the rear, so I blew everything apart to move the trailing arm pivots around until I got the camber sweep I was after. (Third time was the charm, of course.)

The project when back on the Celette to rehang the rear bodywork and finalize the mounting tabs.

While it was mounted on the bench, I repaired and straightened the floors, backdated the tunnel, and worked on the decklid hinges.





I spent a few days researching the available R hinges for the decklid and comparing them to photos of actual 911Rs, and the only ones that were acceptable weren't available at the time. So, I ended up modeling our own with the correct angle and twist (the original parts were L&R, as I discovered on this thread )



I went so far as to design the tooling for assembly before I thought to check my reference photo archive to verify that R7 even used the R hinges. It didn't. R7 uses what amounts to a screen door hinge, in my opinion.

A couple of rounds of modifying locally available hinges and we ended up with something plausible:

[eimkeith]

somewhere in there we had a Cooper's hawk fly into the shop and get herself trapped in the rafters (things stay interesting around here.)

ever wondered why welding gloves are made of leather?

[eimkeith]

So, everything adjusted, tabbed up, and floor and tunnel sectioned in, the MSRSR was completely stripped down once again and put on the rotisserie for the final stretch of welding.







The RSR/G50/930 trailing arm pivots were finalized, as was the RSR pedalbox floor with an extension for a hydraulic clutch master hidden in the tunnel

[eimkeith]

Currently, I'm working on resolving the odds and ends/details on the chassis between other projects.

[eimkeith]

In between all of that, other work has occurred on the parts-side:

We're going to run a muffler on this car (neighborhood tolerance) and heat, so we decided to use the R/RSR big tip muffler (used with megaphones) look. We're modifying a stainless Dansk with our own tips.











(we still have to do the backside work to mate to the 993 heat exchangers we're using on this engine)

[eimkeith]

Additionally, we had the MFI injector blocks/adapters that we designed for this project machined. These came out particularly nice!

[eimkeith]

Backdating the center tunnel allows us to run RS Lightweight seat mounts under the lollipop, but we didn't like the height - so we developed our own line of lowered, RS Lightweight inspired seat mounts for the F chassis.



These have a 30mm drop at the rear! We also used a shoulder bolt in a socket, so as to get away from the common practice of putting a threaded bolt in shear to mount the seat.


And, just yesterday, I finalized the throttle pedal extension, so as to resemble the one in R7:





So all in all, a bit has happened since the last update.

[al lkosmal]

Keith, those MFI injector blocks are very nice. Nice Hawk work too!

[eimkeith]

Originally Posted by al lkosmal

Keith, those MFI injector blocks are very nice. Nice Hawk work too!

Thanks Al!

[Cory M]

good stuff!

[eimkeith]

Thanks Cory!

[cnielsen]

Amazing work Keith! I want one of those mufflers for my ST

[Tom '74 911]

Thank you for taking the time to post an update. This project definitely "goes to eleven", and I appreciate the insight into the level of detail, trick design work and bespoke parts involved. I imagine it's a fun project to work on most of the time - whatever it takes, make it so. If a part doesn't exist, you get to figure out how to make it, sometimes using and learning some pretty cool modern technologies in the process. I'm sure it's not roses all the time, but sounds like a lot of fun... Thanks for sharing.

[eimkeith]

Thanks guys.

[MFX]

I love the attention to detail you are going to on this build. It would be tedious, but I think it will be an amazing tribute when it is done. Great work.