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Said it before, but there is always someone who can take a better photo than you can.
Photos by Ty Milford, Photographer and partner of Rennfilms: http://rennfilms.com A snap shot from a Saturday morning... http://i161.photobucket.com/albums/t...psowugedhf.jpg http://i161.photobucket.com/albums/t...pslew9intb.jpg http://i161.photobucket.com/albums/t...psoji2qny0.jpg http://i161.photobucket.com/albums/t...psnmx0hcpp.jpg http://i161.photobucket.com/albums/t...pstienspce.jpg Cheers Chris |
Front skid pan fitted...finally.
Good fit, and might also help with front to back weight distribution :) http://i161.photobucket.com/albums/t...psfgefkg5l.jpg http://i161.photobucket.com/albums/t...psfj6l494e.jpg |
Hey, Chris - It's great to see you posting here again! Your car is still one of my favorites and it still looks great!
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SmileWavy
Looking back to 2017... All was going great until I could no long find second gear! At first I put it down to the shift coupler, but after re-bushing and adjusting it still persisted. The engine and Gearbox were dropped out of the car and a new clutch and throw out bearing ordered. Strangely the throw out bearing that was fitted was "twisted", no better way to describe it. The clutch would engage but the bearing was at a noticeable angle. Anyway new stuff fitted and the problem fixed...or so I thought. The car still would still not shift into second, it would just about slot in at idle but no chance whilst moving. So we decided to nurse the car to the Emory Campout (the first few sentences of this thread state that I wanted to build something inspired by the Emory specials, so I wasn't going to miss the opportunity to show the car in person to those guys) with some interesting footwork and then investigate further on return. Enroute to the Emory Campout http://i161.photobucket.com/albums/t...psdfbr8oca.jpg The gearbox was removed again and then delivered to German Transaxle in Bend Oregon. The guys at German Transaxle were great and took me through the tear down process... http://i161.photobucket.com/albums/t...pslwloqwsi.jpg http://i161.photobucket.com/albums/t...psh8sxgwzh.jpg http://i161.photobucket.com/albums/t...ps4h5z5qux.jpg http://i161.photobucket.com/albums/t...psb8zrrxvn.jpg |
It quickly became obvious that the Gearbox would need a full rebuild. The synchros were shot as were the slider gears, the gear ratios didn't look too bad but there was wear to the Pinion gears and diff. I was happy for them to rebuild it and they gave me a 2 week schedule...perfect ! Then I got a call saying that it would be better to get a new case rather than machining, some of the pressed races were worn and had play in them.
So I started to look for a case and then came across a complete 911/01 box for sale.....I should have listened to the warning voice in my head but I pulled the trigger and bought it sight unseen. I collected my old Gearbox and associated parts from German Transaxle and said I would be in touch. The "new" Gearbox finally arrived.....but as soon as I opened the box I noticed a big crack around the starter motor housing !! http://i161.photobucket.com/albums/t...psfniogcmo.jpg http://i161.photobucket.com/albums/t...pssutogrua.jpg http://i161.photobucket.com/albums/t...psjnksvzd7.jpg Speaking with the seller he put it down to sloppy FedEx shipping! Around this time I got in touch with Jeff Gamroth of Rothsport racing, I had met him in passing at the Emory campout afew months earlier and he had come out with us on one of the Sunday morning drives. The work that Jeff and his team do is amazing and the shop isn't too far away from work: http://www.rothsport.com I took the two gearboxes to Jeff and immediately he told me the "new" Gearbox was junk..."the only way that can crack is from a rear end impact"...Jeff is a straight talker, but said he would be able to build something out of the parts I had: "How much" I asked ? "Well you need a Gearbox" he said and we left it at that...he did like the Vanagon though :) Jeff called afew weeks later and said the Gearbox was ready...He had used another case and upgraded a lot of internals with stronger parts, installed a new diff, and replaced the synchros and sliders. All in all the Gearbox should now out last the car ! And the price ? Not as bad as I was expecting...especially as on collection it was sitting on a bench next to a 908, two 2.7RS , a Speedster and the two safari 964's :wink: http://i161.photobucket.com/albums/t...pswmj9ir76.jpg So all back together and went for a drive around the block... http://i161.photobucket.com/albums/t...psgsb8htge.jpg http://i161.photobucket.com/albums/t...ps9wun9ddi.jpg Gearbox feels super tight and direct (as direct as a 911/01 can be) and just little blip of the throttle tells us that the carb work made a massive difference :) BTW...The seller of the other Gearbox admitted that the "goods were defected"...I sent it back and he gave me a full refund. There is a moral there somewhere. Onwards! Chris |
On a lighter note...the clock now works. Those double Heuer stop clocks are so overrated :)
Keeping it Modernist thanks to Dieter Rams... http://i161.photobucket.com/albums/t...psvtvhzipn.jpg Also fitted a new Accelerator pedal, a beautiful engineered item from D-Zug. The feel is very different from original rubber pedal, much more on-off feel...the motion and feel is very direct. I also adding a slave spring, which is fixed to the Gearbox case. The spring hooks onto the Accelerator pivot arm and takes out alot of slack feel in the pedal linkage. I still need to dial in the angle on the pedal, there is a lot of options to get it in the right position but it feels good. I will add some skateboard grip tape, just to give abit more underfoot assurance... http://i161.photobucket.com/albums/t...psl6z19zhs.jpg http://i161.photobucket.com/albums/t...psgd3uszch.jpg http://i161.photobucket.com/albums/t...pst47ikh7a.jpg |
A cold New Years day drive.
Idle set higher and Battery charging correctly. Gearbox feels great, as does the improvements made to the fuel delivery. Still afew tweeks needed and might fit a heavier slave spring on new accelerator pedal, but great progress made... http://i161.photobucket.com/albums/t...psmnnumbpe.jpg http://i161.photobucket.com/albums/t...psfthpawun.jpg http://i161.photobucket.com/albums/t...psoxikoom7.jpg Still not 100% sure I have the correct Dipstick fitted... http://i161.photobucket.com/albums/t...ps3gcmhc0u.jpg Sounds good and pulls strong though... VIDEO https://vimeo.com/249418116 |
Solved the Oil issue...11 quarts later and all is good.
So all that was going ok, enjoying the car...getting out and about, meeting up with old friends... http://i161.photobucket.com/albums/t...ps64wezzvu.jpg http://i161.photobucket.com/albums/t...ps6z11zmwu.jpg And then.....Bollocks !!! http://i161.photobucket.com/albums/t...psejmtjwdp.jpg http://i161.photobucket.com/albums/t...psv010phb2.jpg Could have been a lot worse !!! |
The car is looking and sounding really sharp Chris. How much oil did you add though….! Was that a small fire in the filter?
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The car is looking and sounding really sharp Chris. How much oil did you add though….! Was that a small fire in the filter?
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I love that dash!
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Yeah, that dash (and this whole build) is amazing!
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Carb rebuilt and all back together...Had an issue fitting the new Air filters (seem abit bigger than the originals) they started to bow so ordered a new set of Weber rain hats...After three incorrect orders, I eventually received the correct weber base plates and fitted with drilled wing nuts and "locking" springs.
http://i161.photobucket.com/albums/t...ps07npvn9v.jpg http://i161.photobucket.com/albums/t...ps4pononos.jpg http://i161.photobucket.com/albums/t...psyakskban.jpg http://i161.photobucket.com/albums/t...psnqn57yao.jpg |
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The car was fitted with the Elephant racing polybronze bushings at the front and some "modified" (but can't remember why) Superpro polyurethenes on the rear.
They are pretty straight forward to do, just require abit of prep work and then some fiddling around with the supplied washers to get the correct amount of lateral play. All installed and then figure out the grease gun! Got the trailing arms back in the same place +/-, but will do an alignment check once some new tyres are fitted. http://i161.photobucket.com/albums/t...ps74egp0hd.jpg http://i161.photobucket.com/albums/t...pse0tmr4qf.jpg http://i161.photobucket.com/albums/t...ps4uwafhnu.jpg http://i161.photobucket.com/albums/t...sucfevraf.jpeg |
Whilst in there I decided to update the C.V joints. I had never been 100% happy with the original setup that I pieced together with used parts. So I got hold of some brand new C.Vs and axles, remarkable the difference in feel between the old and new. The original setup had alot of play in comparison ! ....
http://i161.photobucket.com/albums/t...s1aht8h48.jpeg Only problem is that the 911 Gearbox is using 914 output flanges (smaller diameter, but compatible with the gearbox) in order to mate up to the 901 stub axles. The 914 output flanges have 4 bolts and 2 pins, so I made up new some pins and will press into place. http://i161.photobucket.com/albums/t...slwr40yux.jpeg |
After that I needed something fun to do...So got hold of a Repro Durant mirror, no original mirrors were harmed in the making of this.
But its true, if you think its difficult to see out of an original, try a repro...guess they are cheap for a reason ! http://i161.photobucket.com/albums/t...syulheyqz.jpeg Guess which race car the inspiration is taken from.....Clue: its Swiss :wink: http://i161.photobucket.com/albums/t...sc82gbgir.jpeg |
Mirror update...Can now actually see out of it !
Talbot style bolted through the window frame...Considered painting it, but I am liking the integrated look https://hosting.photobucket.com/imag...080&fit=bounds https://hosting.photobucket.com/imag...080&fit=bounds https://hosting.photobucket.com/imag...080&fit=bounds Also, again using the benefit of the roller paint job...Fill, Sand, Paint, Buff, Sorted :) https://hosting.photobucket.com/imag...080&fit=bounds https://hosting.photobucket.com/imag...080&fit=bounds https://hosting.photobucket.com/imag...080&fit=bounds |
Decided to revisit wrapping the exhaust manifolds (insert American accent - Headers;)).
It was a PITA first time around and this time was no different...Itching and frustrating, but happy with how it turned out. Still not 100% convinced on the benefits for a road car, but I do like the vintage race car look. The plan was more for temperature management rather than performance gains... https://hosting.photobucket.com/imag...080&fit=bounds https://hosting.photobucket.com/imag...080&fit=bounds https://hosting.photobucket.com/imag...080&fit=bounds Will probably end up having them Ceramic coated... :roll: |
Nice to see updats Chris, glad your still enjoying your fabulous build! I remember when it was a roller sitting in my drivway when you came to look at it and ultimately buy it.
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Nice to see updates Chris, glad your still enjoying your fabulous build! I remember when it was a roller sitting in my driveway when you came to look at it and then ultimately bought it.
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Would love to see the complete exhaust installed , killer vintage race car look !!
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Whilst in and under there I wanted to take look at the driver side rear wheel...It has a slight play to it which I suspected was the bearing.
https://hosting.photobucket.com/imag...080&fit=bounds https://hosting.photobucket.com/imag...080&fit=bounds Both bearings came out ok, but the outer bearing was very loose in the hub...I read that this not uncommon, but this one would fall out with the gentlest of taps on the hub. So I center punched the mating surface and then applied some Loctite bearing retainer and left overnight. https://hosting.photobucket.com/imag...080&fit=bounds https://hosting.photobucket.com/imag...080&fit=bounds Next morning, after the bearings spending a night in the freezer, everything pressed together ok. https://hosting.photobucket.com/imag...080&fit=bounds It's better than it was, but the play is still noticeable, even after getting the castle nut up to 250 lbft ! Next step is top start removing some potential other culprits of noise / rocking actions...Roll bar, shocks etc... |
Next was to improve the Oil return routing.
The car is fitted with a larger, 930 Oil Tank. It doesn't have a front Oil cooler so the larger capacity tank is not a bad thing to have.....Other than trying to work out the correct Oil capacity. In the original build I had to modify the engine bay hole for the filler neck and filter.....In hindsight I should have fitted the earlier tank, the big problem is the thread sizes for hoses and fittings. The later tank uses M30, the earlier tank is M26...In addition the engine crankcase is also M26. Elephant Racing supply M30 - M26 adapters and elbows so fitting is fairly straightforward, the only problem I have had ( or unresolved solution ) is that the return line is a flexible hose that goes up and over the gearbox. After abit of searching I had the plan to fit a later rigid (under the gearbox) pipe with the M30 fittings It need bit teasing and persuading to adjust the bends to clear the gearbox, but it was fairly close...The only problem was that it fouled slightly on the crankcase. https://hosting.photobucket.com/imag...080&fit=bounds A few choice cuts, pipe extending and brazing later it fits and looks a lot cleaner. Just about clears the wrapped manifolds. https://hosting.photobucket.com/imag...080&fit=bounds https://hosting.photobucket.com/imag...080&fit=bounds https://hosting.photobucket.com/imag...080&fit=bounds The M30 elbow allows to fit a small section of the original hose and connect to the tank https://hosting.photobucket.com/imag...080&fit=bounds Solving problems that shouldn't really exist.....but that's part of the fun (to me at least) Onwards! |
...and then Downwards !
So I had put everything back together and did a few loops around the neighbourhood...All felt good. Went out for an early morning drive...pulled onto freeway on ramp, pulling hard, HARDER !!! Then revs began to die ! Pulled onto hard shoulder, then silence ........BIGGGGGG HORNNNNNNNNN!! WOOOOOOSHHHHHH goes past.... S#*t that was close ! I was on the narrowest section of the hard shoulder in a grey car, against a grey wall wearing a grey sweatshirt...not the best situation, but lets focus. Cranked over, cranking cranking but no start. Hooked up the emergency starter pack...Cranking nothing. After afew attempts and pumping the pedal it eventually started and I managed to nurse along the shoulder to the next exit before it died again. Started and then died again...albeit abit closer to civilisation https://hosting.photobucket.com/imag...080&fit=bounds Thankfully I was only a mile from home at this point, but it took another 3 of these "procedures" to limp back home. Thought was that it was either a fuel or ignition issue...After checking everything and getting it started again noticed the fuel pressure (Malpassi fuel filter / regulator) was dropping. So changed it out and ordered a new fuel pump. It was only when I began to pack everything back in the frunk, that I realised the petrol tank breather pipe was full of liquid...In my attempt to clean up the routing of the pipe, I had inadvertently created a P-trap ! The weather had been quite hot recently, so I suspect that some fuel had vaporised and blocked the pipe, creating a vapor lock and not allowing the flow of fuel...The pump would be sucking air, and the faint smell of fried electrics lead to believe that the pump was overheating So tank out and planned a new pipe...The obvious way would be to go through the original factory hole, but the car is running a bigger later tank and as a result the extra volume blocks off the hole...so I drilled a new hole and routed the pipe through there. Was also a great opportunity to clean out and touch up the area. https://hosting.photobucket.com/imag...080&fit=bounds https://hosting.photobucket.com/imag...080&fit=bounds New Facet fuel pump fitted.....sounds like a bag of spanners ! I have never really been happy with them, this is the 3rd one I have used and they all sound like they are going to explode, I even updated the isolated fixings, but it still sounds the same. https://hosting.photobucket.com/imag...080&fit=bounds I read that the Facet pumps prefer to push rather than pull the fuel through, but I have seen many early cars and modified cars with the pumps in the engine bay. However some research lead me to order a Pierburg front mounted pump. It is supplied by Redline / Weber... Its a lot smaller, working on a vein system...All I had to do was make a bracket which attaches onto the steering rack and also fit a 180o elbow which cleans up the hose routing. Wired in easily to the dash switch.....at least we had the foresight of labelling the wiring. Tested the pump and the noise is amazing...In the sense that it is quiet compared to the Facet, also it is a constant whine as opposed to an erratic banging. https://hosting.photobucket.com/imag...080&fit=bounds https://hosting.photobucket.com/imag...080&fit=bounds https://hosting.photobucket.com/imag...080&fit=bounds Onwards again !! |
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