So great to see other designers her doing killer work! I'm a product designer here in Michigan and recently picked up an '81 SC as my next rally car project...

LarryParkerDesign

Beautiful, beautiful work!

Just WoW!!! Great work....

I like your windshield fluid ... :D who makes whose? Thank you.
http://i161.photobucket.com/albums/t...ps9f0213ee.jpg

Washer bottle is nothing special, I got it from:

Windscreen Washer Bottle Kit 1.2 ltr - WBOT

I then made a custom bracket for it. The bottle is nice as the pump motor is integrated into the mold, making everything clean and simple.


Chris

I have been hoping for an update on your project for a while now. So glad to see that it's still coming along. I can't wait to see how it's all going to turn out. As always Chris, great work.

Fantastic build Chris, very inspirational to see someone do every bit himself.

Who was the source of the Repa Harness?

Thanks Rob.....I will PM you the details of the Harness maker.


Chris

Love the horn button, and the lap belts now make much less concerned! Stout anchoring too.

Great job - thanks for sharing.

Brent

79 - 911

this is very motivating.
i should get to the garage and put my engine back in my car.

it is your attention to details that makes this bare car so interesting.
good job, great stuff.

There are guys here who really have gold in the hands.

Congrats for the work done (and to come).

Holy wow, this is so inspirational!

I registered here just to post this :)

great BUILD.

Did I read this right that you did not know how to weld and do body work prior to this? This is absolutely a beautiful work of art... KUDOS to you... :)

Thanks for the kind words guys, its always encouraging to get positive feedback. Yes, I did learn to weld on the car.....Lego as a kid has alot to answer for :)

Afew recent updates...


Always good meeting up with old Friends...

http://i161.photobucket.com/albums/t...ps58f439bc.jpg


Afew months ago David Hanning dropped in to say hello....Who is David ? The story is that I bought the Grey car off David back in 2007 in Portland USA, I had previously bought the set of Fuchs' off him which are now on the red car. David transported the car to my house free of charge, and when the time came showed me how to set up the Welder to get me started. A year later, when I was getting ready to move back to the UK, I sold the original Wings, Bonnet, Decklid and my Welder back to David.....and passed on some Welding advice :wink:

So yes, the guy above is responsible for getting me in this mess :)

We have stayed in touch over the years, and shared many ideas. David decided to come over to Germany this year as part of his Self-Birthday present and visit Relatives he has here. After visiting Porsche, Mercedes, BMW, VW Factories and Museums, he found time to drop in to say Hi.

An afternoon of Coffee ( Tea for me ) and cake, with an evening of German Beer, Steak and much Car chat and Tyre kicking inbetween.


Abit of a personal story I know, but I like it :)


Chris

Accelerator rod, guide bushings for the centre tunnel.

10 euro each from Porsche.....Or 1 euro for 3 when using Hard-Rubber Home brew bungs, and then whittled down on the sanding wheel

http://i161.photobucket.com/albums/t...ps39a4c54e.jpg


I am not cheap, but every little helps :)


Chris

Always good picking up something much needed for Gratis ( Thanks David ;) )

Petrol sender plug sent from the USA. Custom form said Auto Electrical, Value $ 3.00

http://i161.photobucket.com/albums/t...psb1b9be4a.jpg


HOWEVER It didn't mention the free Scorpion that came with it !! :eek:

http://i161.photobucket.com/albums/t...ps5b17604d.jpg


Chris

Rear screen went in like a dream-ish.....at the 2nd attempt :rolleyes:


Tools for the job:

- Plastic coated Clothes Line
- Childs Ikea Plastic knife
- A modified hanging 'S' thing I found in the Kitchen

http://i161.photobucket.com/albums/t...psa8467cc3.jpg


Missing from the picture:
- Spray Bottle with diluted soap solution
- Rubber Mallet
- Patient Assistant with strong Thumbs!
- Afew choice words


2 hours later, it is in

http://i161.photobucket.com/albums/t...psb4c75cb6.jpg

http://i161.photobucket.com/albums/t...psc7cb4026.jpg


As everyone says, ONLY use genuine Porsche Seals. There is a cheap Ebay seal now in the Cellar, whilst trial fitting it the fit was shockingly bad! Great care was taken to make sure that the Chrome was properly inserted before starting the fitment, but it still required abit of tapping down with a Rubber Mallet after the seal was finally in place.

http://i161.photobucket.com/albums/t...pseea54f16.jpg


Hopefully I won't need these now, but I couldn't resist fitting the Check 'Rabbit' Straps.....I do like the look of them

http://i161.photobucket.com/albums/t...ps07ae72a5.jpg


Available from a Builders merchant near you :wink:

http://i161.photobucket.com/albums/t...ps7618f125.jpg



Chris

And abit more of an in depth look...


This is only my method but it seems to have worked. As I said before, I was too busy swearing and trying to stop the bleeding to take any pictures during the process....not to put you off :)

I am not sure how to remove the existing glass and seal, from memory I cut out the seal with a Stanley knife when I first bought the car. Also you may need to buy new chrome trim, it is difficult to remove and reuse without bending it too much.

So the Process:

- A Patient Assistant with strong thumbs....and a solid box to stand on, so they can apply more pressure when needed.

- Have a bowl and spray Bottle of diluted Washing-up liquid ready

- Place glass topside up on an old car tyre

- Fit a GENUINE Porsche seal to the glass

- Insert Clothes Line into groove. Start on bottom edge at 6 inches to left of centre. Leave about 12 inches hanging out (don't start :rolleyes:) and run around whole seal, overlap when you get back to the bottom, leaving another 12 inches free and put tape on this end.

- Fit Chrome trim. Wet finger with Washing-up liquid and rub along groove first. Take time to make sure it is properly fitted into the Groove, you will hear it 'Click' in. It will Pop out again slightly during fitting, but it is worth the effort to fit it correctly at this stage

- It should now look like this:
http://i161.photobucket.com/albums/t...ps063bdaf9.jpg

- Place some Washing-up liquid on the Lip around window frame of the Car.

- Place Glass with everything fitted onto Car. Spend time to make sure it is central, and make sure the hanging ends of the Clothes Line sit onto the Parcel Shelf.

- The Seal will sit proud of the body and nowhere near the frame Lip. Push on top of the seal, especially by the roof to get it somewhere near the Lip. Careful not to Pop out Chrome Trim

- Now the FUN abit !

- With your assistant pushing here, and you inside the car:
http://i161.photobucket.com/albums/t...ps97d5692d.jpg

- Start pulling out the length of Clothes Line with tape on. Pull at 90 degrees to the Rubber, pulling directly towards yourself. GO SLOWLY...The idea is that the assistant follows you along the seal, applying pressure as you pull. Go really slowly around the corner. Continue 6 inches up the side, and then repeat the process with the other Clothes line Hanging end.

- This is what you are trying to achieve:
http://i161.photobucket.com/albums/t...ps802f37b5.jpg


- Now it gets tricky. Go back to the other side and continue up to the top corner. The seal will sit Concave on the glass, but it needs to sit Convex against the body. Spray some Washing-up liquid against the seal and body. We managed to continue fitting the screen and then run a Childs Ikea Plastic Knife under the seal to pop it into the Concave position. HOWEVER I think it would be possible to do this process with the Knife whilst pushing down on the seal, just depends how strong your assistants thumbs are:

http://i161.photobucket.com/albums/t...psacac940d.jpg

http://i161.photobucket.com/albums/t...ps3dd4f0fb.jpg

http://i161.photobucket.com/albums/t...ps79d1f75d.jpg

- I also made a Hook which helped 'Tweak' the seal into place from inside:
http://i161.photobucket.com/albums/t...psa8467cc3.jpg

- Copy on the other side, and you should be DONE !

- You will now probably need to Tap down the Chrome trim with a Rubber mallet, just take it easy :eek:

- Final look inside should look like this ( I have no Headliner )
http://i161.photobucket.com/albums/t...ps4041d398.jpg

http://i161.photobucket.com/albums/t...psd68bbf70.jpg

- It took us 2 attempts. The Tricky area is around the those top corners !
http://i161.photobucket.com/albums/t...ps07ae72a5.jpg

Chris

You know you are addicted when you start making your own Spanners...

32mm 'Thin' shaped spanner made at lunchtime...Used to nip up the Oil return reducing adaptor, and then hold in place whilst the 90degree Hose fitting is tightened...

http://i161.photobucket.com/albums/t...pse3318d3e.jpg

http://i161.photobucket.com/albums/t...ps4f0f69e3.jpg

http://i161.photobucket.com/albums/t...ps61304e65.jpg

http://i161.photobucket.com/albums/t...ps82afb996.jpg


But I am happy with my custom Strut bar, I do like those Rose joints...

http://i161.photobucket.com/albums/t...ps4341cbb7.jpg

http://i161.photobucket.com/albums/t...ps4bb82752.jpg

http://i161.photobucket.com/albums/t...ps7a174587.jpg

http://i161.photobucket.com/albums/t...psee109735.jpg


Cheers
Chris

This is one of, if not my most favorite project on Pelican. Absolutely a work of art.

Very nice work Chris. Subscribed

Henry

They are Heim joints if you are in Germany, Rose joints if in the UK. ;)

Any updates? :)

Heat wrapping Exhaust Headers, not something I want to repeat soon...


Happy with the result though...

http://i161.photobucket.com/albums/t...psdd8beb32.jpg

http://i161.photobucket.com/albums/t...ps5d78cdb4.jpg

http://i161.photobucket.com/albums/t...psc9d8b566.jpg

http://i161.photobucket.com/albums/t...ps181737f3.jpg

Nearly ready.....( so very nearly )

http://i161.photobucket.com/albums/t...psac01adf1.jpg


http://i161.photobucket.com/albums/t...ps9e84a3ae.jpg

Cheers
Chris

das ist mit ABSTAND der coolste und detail-ingenieuseste Wiederaufbau, dem ich bisher online (und überhaupt) beiwohnen durfte!

ich verneige mich, vor dem Projekt!

Und: der RAF-Schriftzug am Heckdeckel ist der HAMMER!

DANKE!

(in english: I said this thread/built is AWSOME !!)

Oder darf ich sagen, dass ihren RAF Roundel ist die Hunden Baelle? Johann

Are those the steel wheels or the Al ones? The Al ones are lighter than Fuchs, but I've always wondered if they are strong enough to be safe...

Those look like a set of 16" space savers. I have a set I'm not gonna use. Were urs widened?i

Darf ich sagen affengeil ��

The wheels are the Aluminium option...16x5.5. I have spoken to a few guys who have used them on 356's and also a 911, they have reported no issues....but I do have a spare of Fuchs just in case.

I also need to convince the German T.U.V guy that they are ok to use.


Chris

Some historic references/Data must be provided.
But I think it will be one minor issue regarding the overall midification to the car.

;-)

Was it hard keeping the heat wrap pulled tight as you got to the joining of the pipes? Were you constantly wrapping and unwrapping and then rewrapping to keep the tape tight?

The wrap is not that difficult to put on, it is just abit annoying. Basically you will need twice as much as you think, and it will take twice as long.

Before starting it is worth PLANNING your route and direction of travel. Start at the engine flange, you will then find that you will need to switch from wrapping a single pipe and then start wrapping 2 pipes. Hold it in place with a temporary zip tie, and then start the next pipe. You will then overlap the area you have just done, remove the zip tie and then continue, when you have finally finished use metal exhaust ties ( I hope that makes sense :confused:)

It is recommended that you wet the wrap first which helps mold and shape it, I soaked the roll in warm water for 20mins before starting. Basically you cannot put it on tight enough, and yes you will find that you constantly need to wrap and un-wrap abit to get it tight, especially when you go around the bends....I managed to twist the wrap whilst it was on the pipe, abit like giving someone a 'Chinese burn' which tightened it up

I used 50MM wrap, 25mm is available which would go around the bends abit better but you will need a lot more.

As with all things, patience is key


Cheers
Chris

So was this, THE weekend ?

Kill switch Clock delete looks good and purposeful...
http://i161.photobucket.com/albums/t...ps66f0d119.jpg


Warning signs everywhere...
http://i161.photobucket.com/albums/t...ps71b75889.jpg


Oil warmed up, before 7 litres went into the tank...
http://i161.photobucket.com/albums/t...psd8bc111e.jpg

http://i161.photobucket.com/albums/t...ps9d0171ab.jpg


Germanys finest 98 octane added...
http://i161.photobucket.com/albums/t...ps7d455f38.jpg


Now I am not going to lie, the next bit is abit of an anti-climax. During the final checking we noticed that the Oil pressure gauge was going abit mad. Basically the Oil pressure sender is knackered, I tried to fit the sender from the 912, but it didn't work, so a new sender is ordered and will be here this week.....I didn't want to risk starting it without knowing if there was any Oil Pressure.

HOWEVER last evening.....as the Sun was setting, the Birds were signing and the Planets aligned, this happened.....not THE video I wanted to post, but an encouraging sign that maybe, just maybe it will start.....soon :)

( Spark Plug leads disconnected )


VIDEO
http://i161.photobucket.com/albums/t...ps097025f5.jpg



O' and I need a new Oil Tank, as there is Oil coming out of at least 2 pin holes

Cheers
Chris

Right then, after afew set backs of a faulty Oil pressure sender and sticking Carb floats, yesterday was eventually the day that we tried to start the car in earnest...and after a week of glorious sunshine, it was quite fitting that it would be pouring down for this Baptism.

So attempt 1:

A few points to clarify...Mrs Jury had been warned that it might BANG and POP abit but should just keep filming whatever happens. Secondly she states that I have been working on this for 8 years...its ''ONLY'' been 6 !!!


VIDEO https://vimeo.com/89192311

http://i161.photobucket.com/albums/t...psd22e16e2.jpg



So attempt 2:

Actually it was about attempt 7, and Mrs Jury had been replaced by a Wheelie bin and Gaffer tape...love her to bits really :)


VIDEO https://vimeo.com/89192312

http://i161.photobucket.com/albums/t...psc4f89837.jpg



Well we got some impressive smokes rings but that was about it. We tested all the Spark plugs and we were getting really good sparks. We had Fuel going in and Air.....Then I started reading about static timing, I have a feeling that hand cranking the engine has moved the TDC which has thrown out of sync the firing order...



On a positive, the Oil pressure was great !


Onwards!

Cheers
Chris

So l last week I had an afternoon off work to look after the kids After 2 hours at the swimming pool my wiring man, Phil, called to ask if we should have another attempt at starting the car. Phil shows up at 5:05pm

From our failed attempts last weekend, we worked out that the Dizzy was 30 degrees out ! We were trying to fire on Cylinder 1, but actually we were firing halfway down Cylinder 6, no wonder it didn't start :roll:

So earlier in the week we hand rotated the engine to TDC. We then removed and refitted the Dizzy and got the rotating arm aligned correctly.....time to see if it worked.....


VIDEO https://vimeo.com/89636087

Spot the hair continuity error :)
http://i161.photobucket.com/albums/t...ps793c79f4.jpg


Hmm ???? It sounds and smells better, and there are no smoke rings this time, but still something is not quite right

Phil: '' Lets rotate to TDC again, I think the rotating arm might now be at Cylinder 4''
Me: '' Whatever you think Phil, the kids have nearly finished their Tea and I need to get them in the Bath before Rebecca gets home ''

Rotate to TDC , Dizzy cap-off and Hey presto the arm is pointing to Cylinder 4. Remove Dizzy, rotate and replace....

So what happened next .....

The smoke rings from the exhaust are stellar!