I appreciate that, Al!

and a quick update for today (taking most of the day off to get a break before this week's big push):

Spent some time harvesting backdate metal for the door tops; the RSR door panel leaves the top of the door exposed and the contours are significantly different between the '87 chassis and the '73 era doors.

http://forums.pelicanparts.com/uploa...1430060379.jpg

(please ignore the poorly thought-out initial cut) I'm considering using more of the early door on the passenger side to simplify the positioning and cut-in.






And here is how she sits going into the week, after just over 60 hours of panel fitting. I still have yet to turn the welder on, and there are 7 more brackets/tabs that need to be spotweld-drilled and removed before I do so.

http://forums.pelicanparts.com/uploa...1430060695.jpg


Here's the obligatory shot of the metal that has been cut out of the '87 so far to visually backdate the important areas on this project:

http://forums.pelicanparts.com/uploa...1430061045.jpg

In addition to grafting in the donor panels, there is still fabrication to be done on the oil cooler/front latch panel and the left hand battery box areas. Then the RSR sway bar, ignition coil mounts, trailing arm mounts, and rear crossmember reinforcements can be installed. I hope to resolve all of these this week.

Finally, the tub will be seam sealed, the carbon body work re-installed and bonded to the sheemetal, and the hood pre-fit and drilled for the dry-break penetrations - then she's off to the mold shop for the second run of fender molds, and then off to paint!

:cool:

Subcribed... How the heck did I miss this cool thread?

Hi Mark! I'll be talking about the cockpit, and more specifically the steering wheel in short order; feel free to chime in where appropriate when we get there! ;)

OK, more backdate work on the doors - including finally breaking our door hinge pin puller and spending a part of the day on repair.

I realized that I should have made my donor panel for the driver's door more generous, and subsequently cut in another section:

http://forums.pelicanparts.com/uploa...1430258550.jpg


Became smarter on the passenger side:

(donor door and passenger door)
http://forums.pelicanparts.com/uploa...1430258607.jpg

http://forums.pelicanparts.com/uploa...1430258672.jpg

some of the under structure has to be transferred over as well.

http://forums.pelicanparts.com/uploa...1430258754.jpg

and here is the panel, fit and ready for welding in:

http://forums.pelicanparts.com/uploa...1430258816.jpg

we'll be using early hinges as well, as there is a significant visual difference between the early and late hardware; the early hinges used pockets that the internal hex bolt heads fit into, whereas the later hinges used an external hex bolt with a washer base that sits atop the hinge, allowing for larger holes to aid in door alignment.

http://forums.pelicanparts.com/uploa...1430259037.jpg

(early hinge in blue)

This is one of those things: once you've seen it, you see it. So we're addressing it.

http://forums.pelicanparts.com/uploa...1430259114.jpg


And also, for no reason at all other than they arrived today, here is a picture of our new 18" Wheel Product. Check out the Fuchs-style soft lip on these things!:

http://forums.pelicanparts.com/uploa...1430259217.jpg

The Zuchs aren't for this project; but I cannot wait to see what folks use them on! :D

Eimkeith, you can DEFINITELY post pics from Tapatalk. See?

http://images.tapatalk-cdn.com/15/04...23ecb294e2.jpg

Instead of writing a reply at the bottom, click the "+" icon to the left.

http://images.tapatalk-cdn.com/15/04...abb9261fe6.jpg


Sent from my iPhone using Tapatalk

http://images.tapatalk-cdn.com/15/04...5238df5207.jpg

Like this?


keith.

(sent from my rotary dial phone.)

Thanks!


keith.

(sent from my rotary dial phone.)

Thanks for taking the time to post some updates for us. Love the pic of the scrap pile. That tells it all.

my pleasure.

Why didn't you just use the whole early door, instead of sectioning off bits? Because the newer one is galvanized on the outer skin?

Several reasons; primarily to take advantage of the factory side impact protection and rust-free condition of the late door.
On top of that, rust-free early doors are precious now, should be saved for original cars in my opinion.
There are still plenty of rusted-out early doors available to provide donor metal for backdating, though!
(Don't throw any early stuff away.)


keith.

(sent from my rotary dial phone.)

Wow Keith, I just saw this thread and read the whole thing in one sitting. You guys are pretty talented. I had no idea so much time and work went into developing parts. It's interesting how you're using high tech tools to recreate '73 parts in 21st century materials.

Looking forward to seeing how the car turns out. Speaking of that...as I was reading the posts and watching the years slide by, I was wondering what you tell the "client" when he calls and says, "It's been 7.5 years...is my car done yet?".

Yes this one has been a big one; it's gone places neither we nor the client imagined it would, and has become a focus for me in particular in the last few years.

I believe we're in the home stretch on this project though: we now have clear build objectives, honed by the previous changes in scope and direction; we've completed the (multi-year) design work on most of the unique bits that are to be produced for this Mary Stuart recreation (most, not all. ;) ); and we now have the benefit of partnership with a client who is in a position to make it happen and is just as enthusiastic about pushing the envelope on the old stuff while staying true to its spirit as we are.

Hindsight being what it is, some time could certainly have been saved if we initially set out to build the final iteration (even irrespective of the design activities) - for instance, the metal backdating I'm doing at the moment is the second round of such work; had we known that this project would require this level of detail consideration, this metal work would have been long completed. Likewise for other aspects of the project.

- then again, we like to see clients dialogue with their projects, it's the process of making the builds theirs and where the unique stuff comes from, I think.



keith.

(sent from my rotary dial phone.)

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

Passenger door finished and mounted.


keith.

(sent from my rotary dial phone.)http://images.tapatalk-cdn.com/15/04...306c05e5cd.jpg

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

So as a result of posting this, I've just been informed by folks more knowledgeable than I (folks that were intimate with 911s in 1973 :D ) that the bolt changeover to the external hex and non-recessed hinge actually occurred in mid-year '72. Therefore, being a '73, the hinges I removed would have been the correct hinge for the Mary Stuart RSR. :o



However, due to the MS being a factory prototype/development chassis, all manner of oddity could (and probably did) occur. Does anyone have historic photo reference tucked away of the Mary Stuart door jamb for the sake of accuracy?



Unless some photo evidence appears to the contrary, I'll be re-installing the original hinges tomorrow.



I must say, I'm pleased that the thread is now assisting the build ;)

Both doors complete, mounted, and gaps set to factory spec. (4mm)

http://images.tapatalk-cdn.com/15/04...1eaedc9f19.jpg

http://images.tapatalk-cdn.com/15/04...84de91a583.jpg

http://images.tapatalk-cdn.com/15/04...fb8aa92b3c.jpg


keith.

(sent from my rotary dial phone.)

Passenger door hinges replaced with correct ones this time. ;)


keith.

(sent from my rotary dial phone.)

Do you have a source for the correct triple square cheese head bolts? Can you still get them from Porsche? IIRC, there are two types, one with a knurled outside edge and one plain.

They aren't available from Porsche; we have a small stash of the squirreled away - I believe Ed Mayo has a source (he's the go to guy for vintage detail stuff if you didn't know. ;). )


keith.

(sent from my rotary dial phone.)

Thanks Keith, I have a some left from parting out cars but would be nice to have correct stock available. With the bubble we're in, I have to believe that there's a secret society parts horde somewhere.

I think that's likely; little hordes here and there.


keith.

(sent from my rotary dial phone.)

This is great! Would love to highlight this build on our social media outlets. When do you think the project will be finished?

that would be fantastic, and appreciated.

looking to complete before the end of the year.

Great! I will keep an eye out for updates here.

Working on the trunk latch panel/oil cooler duct today.

The previous iteration of the build was to use a fiberglass 'backdate' hood: a long hood skin on short hood support structure, so as to work with the G chassis front latch panel.

Since the trunk compartment is now a significant detail area for build authenticity, the latch panel must change.

After cutting away the old stuff, jigging on the Celette allows for some straightening, leveling, and correcting of the front of the car

http://images.tapatalk-cdn.com/15/05...e4c15d18cb.jpg

^ In this photo you can see where I've removed the upper G Chassis reinforcements that run roughly horizontal from the strut towers to the front of the car, as these were not found on the long hood cars. (lots of spot weld drill work) You can also see the vacuum-assist delete panel I've cut-in on the bulkhead in front of the driver. Aside from the contours of the vacuum booster sheetmetal being a glaring distraction when trying to pay homage to the original car, the twin RSR MFI fuel pumps must be mounted here - a major visual component of the RSR trunk.

You can also see where I'm cutting in for battery boxes, which will be deleted with blockoff plates per the Mary Stuart RSR.

(In the photo below you can see where I need to finish the upper decking work above the engine rooms - my usual weekend work)

http://images.tapatalk-cdn.com/15/05...ba9c4a602e.jpg

That's enough for Saturday! ;)


keith.

(sent from my rotary dial phone.)

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

Back on the oil cooler ducting today.

This is what we're after (2.8RSR photo from Armando's site):

http://images.tapatalk-cdn.com/15/05...abda92b78c.jpg

The cooler duct is lower and wider than our first iteration for this car, and ours was offset to accommodate the battery in the stock location.

The Mary Stuart RSR used the smugglers box for the battery, and ran the oil lines through the trunk compartment as shown above in the 2.8. We need to reproduce that for our trunk also.

http://images.tapatalk-cdn.com/15/05...16451a4dbe.jpg

^This is where I started this morning. You can see that we previously frenched the oil lines through the corner of the front of the trunk to clear the tight contours of the early RSR bumper. That has to be removed & repaired along with the existing duct to better reproduce the MS trunk.

So everything comes back out.

http://images.tapatalk-cdn.com/15/05...a03c16002b.jpg

http://images.tapatalk-cdn.com/15/05...bbcbd7f771.jpg

I did some corner repair (harvested the corner from the donor car, cut it in, and welded it in place - it will need some rust amendment and final trimming just before the duct goes in) and took some measurements for width at rear, centerline, and height and width where the duct crosses the vertical plane created by the trunk sides and my jigging.

I made a quick trip upstairs to the office and sketched up my duct to get dimensions for making a template.

http://images.tapatalk-cdn.com/15/05...c731c2d164.jpg

Now that I've worked my way to a clear plan for the duct, I think that's enough for Sunday. :)

http://images.tapatalk-cdn.com/15/05...ef18700642.jpg


keith.

(sent from my rotary dial phone.)

http://images.tapatalk-cdn.com/15/05...b5390298b2.jpg

Bent this thing up this morning. Going bigger to give us room to work with on cooler sizing/hose routing.


keith.

(sent from my rotary dial phone.)

Oil cooler duct wasn't particularly cooperative; got that thing cut in, positioned, and tacked this afternoon:

http://images.tapatalk-cdn.com/15/05...3452f0629d.jpg

Before anything on the front end is finished welded, the hood will be aligned and gapped to double check everything.

We're using a reproduction fiberglass hood with balsa strips, reminiscent of the old Porsche motorsport part. Since I'll be cutting holes in it, I'd be hesitant to use an original hood on this project, even if one were available. This reproduction is probably significantly thicker and heavier than the original, but it should maintain its shape better at speed, and is still a remarkable weight savings over a metal hood!
(I'll weigh it when it is removed.)

http://images.tapatalk-cdn.com/15/05...99e2a3ac2e.jpg

http://images.tapatalk-cdn.com/15/05...1d79837349.jpg

Hood adjustment first thing in the morning.



keith.

(sent from my rotary dial phone.)

This thread is one big dream !!

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

Thanks!

Setting some panel heights and gaps this morning before anything gets welded.

http://images.tapatalk-cdn.com/15/05...52ea8d4809.jpg

http://images.tapatalk-cdn.com/15/05...abd52b65eb.jpg

It's a process with an aftermarket hood; were also using aftermarket fenders, and while the passenger side is pretty good, the drivers' side is a bit shape-challenged. :(

I'm working toward setting all of the panels before trimming the hood for correct gap.

I'll also be removing the front latch panel bumper seal plate and reattaching it to make it level. :/


keith.

(sent from my rotary dial phone.)

Looking good!

What aftermarket hood is that (if you don't mind sharing)? Interested to see what cooler you use and how you set it up in that duct, as well.

I need to do all of these very same things on my '70... front pan, tank support, front latch panel, cooler duct, fenders, hood, everything! Some great inspiration on even just this page!

The hood is Getty (who we recommend if you have to have fiberglass.)

Just finished wrangling the drivers fender and door hinges to get the gaps within factory specification and the 911 contours back in shape where the door/cowl/hood and fender blend into each other.

http://images.tapatalk-cdn.com/15/05...c9469e9b4a.jpg

Back to the front.


keith.

(sent from my rotary dial phone.)

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

Hood roughed in.

http://images.tapatalk-cdn.com/15/05...ad51d3fc67.jpg

http://images.tapatalk-cdn.com/15/05...c03b53c792.jpg

http://images.tapatalk-cdn.com/15/05...a5d000ca03.jpg

http://images.tapatalk-cdn.com/15/05...a1a89b9b6a.jpg

http://images.tapatalk-cdn.com/15/05...e96fa66037.jpg


Back on oil duct tomorrow.


keith.

(sent from my rotary dial phone.)

Still gapping and setting panels this morning; chasing millimeters.

Took a break and made these to speed it up (I was getting too granular with the calipers):

http://images.tapatalk-cdn.com/15/05...180208e6c7.jpg

More later.


keith.

(sent from my rotary dial phone.)

Remember when I said the driver's side aftermarket fender was shape-challenged? It is set and gapped, needs some additional attention to properly follow the hood contour at the seal edge, but at least the horn grille and turn signal mount is correctly formed.

Unlike the passenger fender.

http://images.tapatalk-cdn.com/15/05...117f180deb.jpg

Off day at the body part factory I guess? I'll be cutting the divider loose and resetting all that stuff tomorrow, along with cutting off the hood seal tab and leveling that.

I've got to get the fenders finalized before I can final trim the hood, have to finalize the hood before I make the front end stuff permanent. Then I can pull all this stuff of and get back to chassis fab.


keith.

(sent from my rotary dial phone.)

Quick update for today; worked on the horizontal mounting flanges of fenders today to get them lower in relation to the front bumper seal, then removed the seal flange and reattached it level to the frame jig and fenders.

Started upper oil cooler duct/cooler mounting recess (this deviates from the authentic RSR, but we prefer to pocket the coolers in a bit for bump protection)

Not much to see, but here's where I'm stopping for the evening:

http://images.tapatalk-cdn.com/15/05...42f5a5e57d.jpg

http://images.tapatalk-cdn.com/15/05...ecb45caee0.jpg

And here is how the hood seal fits after adjusting the seal mounting flange:

http://images.tapatalk-cdn.com/15/05...e47f2b0b99.jpg

http://images.tapatalk-cdn.com/15/05...f9f23a74c1.jpg




keith.

(sent from my rotary dial phone.)

Thanks for the updates Keith! I'm following this thread with great interest from the beginning and you seem to amaze me with almost every update.

Thanks! I appreciate the feedback.

Made progress on the oil cooler duct (oil cooler mount recess part) today; had to dust off the panel welder and give it some exercise:

http://images.tapatalk-cdn.com/15/05...dcb870524e.jpg

Then I called it a day and went to a local cruise-in. (There were about 5 euro cars in sea of muscle).

http://images.tapatalk-cdn.com/15/05...23b2450f03.jpg



keith.

(sent from my rotary dial phone.)

Making some progress on the duct this morning.

http://images.tapatalk-cdn.com/15/05...fb0e4896e8.jpg


keith.

(sent from my rotary dial phone.)