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.

those are great looking flares.

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?

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.

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.

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.

wow, panels turned out great!

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.

want to sell that clip?

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):


http://forums.pelicanparts.com/uploa...1429667478.jpg

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

http://forums.pelicanparts.com/uploa...1429667605.jpg
http://forums.pelicanparts.com/uploa...1429667618.jpg

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

regards,
al

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:


http://forums.pelicanparts.com/uploa...1429668855.jpg

http://forums.pelicanparts.com/uploa...1429668889.jpg

http://forums.pelicanparts.com/uploa...1429668921.jpg


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):


http://forums.pelicanparts.com/uploa...1429669023.jpg

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.

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.

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.

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

http://forums.pelicanparts.com/uploa...1429696798.jpg
http://forums.pelicanparts.com/uploa...1429696822.jpg

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

http://forums.pelicanparts.com/uploa...1429696867.jpg

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.)

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! :)

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.

Here are a couple of photos of the front bumper sculpt:

http://forums.pelicanparts.com/uploa...1429708697.jpg

http://forums.pelicanparts.com/uploa...1429708741.jpg

and one during brake duct locating:

http://forums.pelicanparts.com/uploa...1429708806.jpg

I wish! You have to have Emory-deep pockets for that kind of equipment ;)

Ha!! :D

I really dig those front bumpers, by the way!

Thanks. The front has been refined since - closer to the historic silhouette without reproducing the part that really annoys me. :D

Testing (tapatalk.) Can I upload images this way?


keith.

(sent from my rotary dial phone.)

apparently not. bummer, since that would reduce a step in posting photos...

OK, thought I'd jump forward and show yesterday's work. (Anyone who has done this knows how tedious this is.)

Removal of G Chassis Bumper Mounts (SO many spot welds!):
http://forums.pelicanparts.com/uploa...1429795877.jpg

http://forums.pelicanparts.com/uploa...1429796020.jpg

http://forums.pelicanparts.com/uploa...1429796074.jpg

Also finished up proofing an alignment tool for installing 930/RSR pickups on the G50 torsion bar:

http://forums.pelicanparts.com/uploa...1429797196.jpg

http://forums.pelicanparts.com/uploa...1429797300.jpg

We're printing the weld-on bits for mock up this morning while I work on the chassis. Once proven out, we'll make some templates to transfer the cut lines to the steel stock and get the mounts made & installed on the tub.

Keith,

Do you happen to know the weight of the G Chassis Bumper Mounts? I agree - they are a bear to remove properly.

Thanks,

Scott, if I could reassemble them to weigh them, I'd be happy to answer that! As it is, I remove them like peeling an onion. (including the crying ;) )

OK, so that is going to work out nicely.

http://forums.pelicanparts.com/uploa...1429827107.jpg
http://forums.pelicanparts.com/uploa...1429827128.jpg
http://forums.pelicanparts.com/uploa...1429827142.jpg

and got some work done on the rear engine compartment cross member today.
there are significant visual differences between the '87 and '73 chassis here, and since the engine will be framed by this part of the car, changes are required.

fixing the corners:

http://forums.pelicanparts.com/uploa...1429827756.jpg


and removing the strike plate bump:

http://forums.pelicanparts.com/uploa...1429827838.jpg

http://forums.pelicanparts.com/uploa...1429827864.jpg

I found some the photos I was looking for - here is one of Aaron's distributor on our client's 3.9 before sending it off to Kurt to have the ignition system configured:

http://forums.pelicanparts.com/uploa...1429834165.jpg

some of the good stuff from TwinSpark arrived today for this build; won't be long for final assembly on the engine.

Keith, I know I'm probably the 799th guy to say this, but thank you for pulling the curtains back on the process and ideation that is going into this most excellent build.

I've worked in automotive prototyping on the west coast, so this is super fun to watch for me. But I know that these updates take time, and you've invested lots of after work hours adding some mad CAD skills, so I feel we here are really lucky.

Love the MFI direction.

One of these days I am coming by to see this.

Thanks. I really appreciate that.

In regard to that gracious comment; my objective for this thread is to dutifully report the build through to completion, and the reasoning behind the decision-making - I'm planning to be active here for the next several months as I get this car done.

In respect to the revised build objectives; as continuation of the investment in authenticity made via the mechanical fuel injection system; and in respect to the stated goal of honoring the historical theme in an authentic way, we're considering every visual aspect of the project in regard to conforming these areas to that goal.

I'm constantly learning details about the Mary Stuart RSR; research is ongoing and thus the fine points of the build are subject to being altered accordingly; however I feel like the most significant and dominating visual cues of the Mary Stuart RSR 3.0L Prototype have been considered and are being addressed.

For sanity's sake I sort of grouped these into the following broad categories for purposes of visual appropriateness: Body/Engine/Engine Compartment/Cabin/Trunk Compartment

These tend to bleed over into one another. This bleed over is responsible for the recent cutting & welding that has happened (and is still in full swing) on the tub:

http://forums.pelicanparts.com/uploa...1429917849.jpg

and the shrinking of the donor chassis:

http://forums.pelicanparts.com/uploa...1429917913.jpg


The Body category is of course dominated by the signature Mary Stuart collar, the bulbous front flares, and the corresponding bumpers. I'll be posting about the bumpers as the file is finalized and they go into production, as well as during the bonding of the flares to the car, and also the second round of mold-work that is going to be taken directly from the car for better fitting production parts.

However another very visual aspect of the exterior is the dual through-hood fills. Depending on configuration, this was either staggered openings with hinged covers, or symmetrical exposed dry breaks with surrounding aluminum drains.

The Mary Stuart ran the 110L plastic endurance tank, as well as various period fuel cells (likely ATL brand.)

Our client wants to race this car from time to time, so we're building around a Fuel Safe cell, so as to be confident about the availability of replacement bladders going forward. I'm using a 110L plastic tank to properly position the dry breaks (located unused original parts) then making the appropriate fill tubes to the cell.

Here's one of the dry breaks:

http://forums.pelicanparts.com/uploa...1429918027.jpg

and here is some work toward a threaded cap conversion I'm working out (so that the dry break can be unscrewed and function as a regular cap at the gas station):

http://forums.pelicanparts.com/uploa...1429918154.jpg

http://forums.pelicanparts.com/uploa...1429918239.jpg

We're working on a lot of stuff like this for this project, which I'll be happy to post.

Right now I'm up against a deadline on the chassis fab stuff, so that is what my focus is on at the moment, but I want to take the time to explain why I'm cutting up random parts of the car, as well as showing photos of the chaos, so bear with me as I trickle the content out between billable hours. :)

... and yet I took a break from metal work today to pre-fit the engine tin and shroud.

For this project the RSR fiberglass came from TwinSpark (with the slide valves.) This is the first time I've worked with this particular brand, and overall I'm impressed with the weight & consistent thickness. The fit could be better, as I find is typical with aftermarket fiberglass (excluding a couple of notable vendors.)

I spent the day trimming and fitting - some of the fitting necessary because we're installing on a 3.6 case, some due to mis-located holes or over-cuts from the manufacturer.

The shape of the fan shroud and side block offs is particularly good:

http://forums.pelicanparts.com/uploa...1429991833.jpg

(I love the look of natural RSR fiberglass - like the see-through anatomical human models I loved as a kid)

I was able to trim the side panels and shroud for a good fit around the fan housing and cam towers.

http://forums.pelicanparts.com/uploa...1429991971.jpg
http://forums.pelicanparts.com/uploa...1429992130.jpg
http://forums.pelicanparts.com/uploa...1429992177.jpg

- had to trim for belt clearance:

http://forums.pelicanparts.com/uploa...1429992226.jpg

- and for fit over the flywheel area:

http://forums.pelicanparts.com/uploa...1429992287.jpg
http://forums.pelicanparts.com/uploa...1429992315.jpg

All in all, pretty good for a first pass! I have some areas marked for fine tuning during final engine assembly, and still have to trim in the front tray, make an aluminum tab, and make a bridge plate to complete the fit.

Here's where I stopped today:

http://forums.pelicanparts.com/uploa...1429992577.jpg

http://forums.pelicanparts.com/uploa...1429992612.jpg

Awesome work!

Thank you!

Keith,
oh yes!! that is very nice.

regards,
al