Another IROC build - Aussie RHD 3.8

[rennch]

Craig,

Did you just POR over the existing glue and such, or did you take it all down to bare metal?

[nyne11]

subd

[EarlySport]

Originally Posted by emptyo

Craig,

Did you just POR over the existing glue and such, or did you take it all down to bare metal?

The actual floor pans were taken down to bare metal when the sound deadening was removed. I wire brushed the 'sides' manually, and then POR'ed straight over it. Seems to have bonded pretty well - there wasn't much glue left. I'm going to be using a layer of sound deadening mat under the carpets, and I'll lightly glue it to the POR'ed surface.

I've decided that I'll retain/add about 10kgs of sound deadening materials to keep it a little more comfortable on the street.

I'm thinking I might even fit a head unit and a couple of speakers! Crazy I know.. :-)

[EarlySport]

I've been working on the underbody / suspension and interior. I am fitting the later ( 86+ ) larger dash vent to my dash, and doing a custom vent control system. This is really simple - connect the centre dash vent with some custom duct work to the air intake at the hood rear, and plumb the heat exchanger outlets straight to the demist vents. That way I can use the centre vent on/off and adjustment controls ( on the vent itself ) to control fresh air, and the heat lever by the handbrake to control hot air for demist and cabin heating. I get to ditch the factory blower and all associated under hood stuff. What do I lose? A fan for forced air, and footwell air ducts. Sold - I'll take it. I also get a really clean dash, with no air controls.. To achieve this though, I needed to fab up some aluminium cover panels for the dash. Here they are..



You'll note I've also ditched the rear demist (plexi screen), foglight (don't have any), and cigarette lighter (don't smoke). I might retain the handbrake warning light/seatbelt light (which won't be connected). I've also ditched the next to useless SC side air vents. These panels will be trimmed in vinyl. The upper dash, kneepads, and door tops are being done in suede. Yes - that is Dynamat type material on the dash top and front - I hate dash rattles, and the pound of dynamat is worth it to me!

I've finished rebuilding and reconditioning the entire front suspension. This is getting 21mm Tbars, Koni adjustables, Carrera sway, and urethane bushes (from an aussie company - not as hard as poly graphites). The car is running AP 4 piston calipers on Carrera rotors. As I haven't put this stuff back in the car yet, I have a shelf of pretty parts.. :-)



Those headers are for my RS replica BTW.

[SCWDP911]

Oh man, a man after my own heart. I have been planning on something that the last few weeks. I have some old (but new) aluminum signs I bought at a auction and thought it would be a cool look. I have been looking around for an extra cheap set of the plastic pieces to use to make my pattern off of. What gage aluminum did you use. Can you email me some more pics of this? shane@scwdp.com

Thanks and nice work!

[EarlySport]

I know it's been a while since I've updated, but nevertheless work is continuing. The car took a backseat for a while as I worked on other projects.

Front suspension and brakes are now installed. 21mm Torsion bars have been fitted with Koni struts, and poly bushes. I'm going with 21's rather than a larger bar as the whole front end of this car is fibreglass and is very light. A carrera sway bar has also been cleaned up and installed. All bolts were cleaned up and painted with POR15 for corrosion protection, and I use anti-sieze everywhere to facilitate easy component changes in the future.The car is running AP 4 piston calipers over carrera rotors.





Attention has also been paid to the other end of the car, and the engine bay is now mexico blue, and the underside has been cleaned up and coated in black proof coat.







So now the 3.6 engine and 915 gearbox have been degreased and are awaiting further clean up. Waiting on the shelf are a set of 3.8 P/C's and RSR cams, but I'm holding these off for stage 2 of the build. Right now I just want to detail the engine, do some basic servicing ( new distributor belt, valve timing, plugs etc ) and get it back in the car. Then it's a push to get the interior completed and the car back on the road!

[EarlySport]

Hey guys,

Wow - some time has passed! Unfortunately I have been flat out with work and family and girlfriend commitments, and hence the car had taken a back seat. Suffice to say I'm back into it, and the engine is about to be refitted, leaving the interior to be finished and she's done. All the rear suspension has gone back into the car, complete with 28mm Tbars and Bilstein Sports. New rear wheel bearings and poly springplate bushes round out the mods, together with a Carrera rear sway that will go in when the engine's back in place.



The oil tank has been flushed and reconditioned too, and is now back in the car.



Another project has been to clean up the factory 3.6 plastic intake manifold. I've relocated a couple of the control modules to the rear of the manifold out of sight, and am simplifying the vacuum feed for the power brakes. The wiring will also be partially hidden, rather than hanging off the metal bracket normally at the left front of the engine.





Lastly here's the long block ready to go back in, with mexico blue fan and valve covers.




The engine will be back in soon, and hopefully wheels on, and then it's onto the interior. Think Mexico Blue backed Pole Positions, quick release Prototipo, and much alcantara...

[nameisbauer]

Nice!

[matty74]

howdy earlysport doing a similar thing with my 74 gone wide body, just about to go for respray on the weekend, your story is nothing short of inspiring

keep us posted, where in sydney are you? I'm near sutherland

Matt

[matty74]

Graig,

Is your 3.6 a 964 motor? I have done the wide body work to my car and now want to do the 3.6 conversion, what is the 964 3.6 like?

Matt

[EarlySport]

Hey Matty,

My 3.6 is a 92 964 unit with plastic intake. I only drove the car for a short time prior to the rebuild, but I think the 3.6 is a really nice option for the earlier cars. I own a couple of other 911's and the 3.6 with injection is the easiest motor to live with on a day by day basis. I don't think the power is night and day over my 3.0 with webers and exhaust, but then that's in a much lighter car.

I think the 3.6 in what should be a 1050kg car will be much fun... :-)

Engine is back in the car as of the weekend - pics to come.

[matty74]

look forward to seeing more pics

[Sonjay]

Hi guys! Your car looks great if you need anymore wheels let me know.

[f3nr15]

Originally Posted by EarlySport

... and urethane bushes (from an aussie company - not as hard as poly graphites)...

(Hi Craig; what brand/type of bushings are you using, exactly?)

[EarlySport]

OK guys - it's been a while! Work commitments and women have dominated my spare time, meaning no work on the car for more than 3 months. That said, the last month has seen some serious time put in again, and we are nearing completion.

Firstly, some details regarding the interior. I fabricated a fibreglass cover for the new raised shift tunnel. To re-cap from a few posts back, this fabricated frame moved the shifter up and back 4" for a more ergonomic position. It also neccessitated me fabricating a lever mechanism for the handbrake, to allow the handbrake to be moved up and back too. This lever at present works ona 2:1 ratio, requiring careful adjustment of the handbrake, but I think it'll do the job.

The fibreglass cover has now been trimmed in carpet, and boots refitted.



I've also incorporated a coin tray - but stopped short of a cup holder :-)



I also completed some dash mods. First one was to enlarge the centre vent hole for a late (88+) centre air vent. This will work with my custom lightweight air and heat control system, that I'll detail later. Then I had the dash trimmed in black alcantara, complete with a french seam around the instrument cluster, done in matching mexico blue thread.



The vent isn't secured yet, hence the helping hand. You'll also note the steering wheel quick release for the Prototipo. The door tops have been trimmed in matching alcantara too.



To be continued..

[EarlySport]

Continued...

Finally the engine and gearbox have gone back into the car too. The standard exhaust manifolds are currently in place ( blasted and painted in high temp paint ) with my custom muffler system and twin central exit exhaust. The case etc. has been cleaned up too. You'll also note the new Bilstein Sports to team with the 28mm tbars, and Carrera rear sway.





Up top the intake manifold with all the sensors moved to the rear looks a good deal cleaner than stock. New fuel lines were run throughout the chassis too, and much of the wiring has been cleaned up. Items like new larger ground straps should improve reliability. Fan, valve covers, and coils have been color coded.





And last but not least for this update, the ducktail is now in place. Much lighter than the IROC wing!



Next up is an alcantara headliner, RS door trims and carpet, and custom perspex rear and side glass..

[matty74]

Craig,

You are my hero.

The duck on the wide body, it is a sign of manhood.

Matt

[JohnJL]

Well done. When's her coming out party?

[EarlySport]

I'm hoping to be done in about two months John, with a PCNSW track day and some runs in the immediate future following!

[TunersGroup]

Originally Posted by EarlySport

Hey guys,

As I'm taking some pics of my current build I thought I'd share them with the Pelican community.

A few months ago I purchased a rough 1982 911SC that had some appealing features - an all steel turbo look conversion, plastic intake 3.6L motor, Sonjay 16x10" custom Fuchs on the rear, and AP 4 piston front calipers over carrera rotors, and a nice shifting 915.

Great thread EarlySport. I'm in Sydney too. Are you a NSW Porsche Club member ?

- Adam