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Another RSR build - The begining
I wanted to share my RSR track car build with all the people here that have helped me learn about these wonderful cars and figure out what I'll do and mostly avoid...And hopefully help or inspire any newby wanting to take the step on that OHHH so slipery slope! I know I'll definently need alot more help along the way.
I started with a very clean 74' coupe non-sunroof with only very minor rust in a few places. Striped bare then started rear strut tower reinforcements and roll cage base plates. Just finished tacking those in. Should start bending some tube for the cage in a couple weeks. Build sheet - GT-Racing RSR fg body work - Full tied in cage - Rear camber boxes - Rebel Racing Bilstein coilovers, spring plates and sways - 993 brakes setup - N/A 3.6 with some bolt on stuff ( to start :p ) A few pics, comments and critiques welcome... - First step after stripping was rear seat cutout http://forums.pelicanparts.com/uploa...1241401541.jpg - Then trim the excess, wire wheel the engine bay and cross member to remove all paint and undercoating and make RSR style strut reinforcements. http://forums.pelicanparts.com/uploa...1241402132.jpg http://forums.pelicanparts.com/uploa...1241402261.jpg - Next some sill plates http://forums.pelicanparts.com/uploa...1241402422.jpg http://forums.pelicanparts.com/uploa...1241402485.jpg http://forums.pelicanparts.com/uploa...1241402740.jpg Before I start with tube I'll get the rear Hamlin boxes in for better access. I'm thinking of maybe making them from scratch. Has anyone here done this before and how did it go?!? Once all the tube is cut and fitted, the car will go on the rotisserie and get final welding and finish removing the undercoating. Afterward media blast before epoxy primer. Progress will be slow but steady... I'll keep you all posted! Regards Carl |
Looks like fun! I made my own boxes, crude but effective. It was not hard. I asked Fabcar to make a drawing and Dave was nice enough to fax one over.
http://forums.pelicanparts.com/uploa...1241404974.jpg |
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I think it's the way to go Chris, there are many other places I can spend 600$! They look nice from here... Would you happen to have those drawing still? I could figure it out but I'd love to have the fabcar design as a starting point. Do you have any closer pics?!?
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I don't think I have the diagram any longer, that was many moons ago. However, the design is simple enough - I bet if you looked at the pre-made weld on versions of these you would "get the picture" ;)
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Ya, sure know what you're saying!! With the iron worker and break I should be able to make these pretty easy. But could you tell me what the total travel of the slotted hole should be? And the position of the arm seems to move back a few mm, is this correct?
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In my case I installed turbo trailing arms, which required a different geometry to get started. I
If you can find them I recommend using them, much stronger. I'll see if I can dig up some other pics but it may take a while. |
I made an executive decision not to go with 930 arms, I wanted to but didnt. The cost and rarety make the advantages not worth while for me... If I notice any repeated failure of the 911s I'll just find a way to reinforce them. Makes it a little easier on the crash budget! So tonight I'll start on those camberboxes and see what we come up with.
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Here is a really quick sketch of what I had done:
(see next post) I'll try and add some more description later - but these are simple and they worked great! |
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Thanks for the sketch Chris! One question, why does the adjustment bolt have a left and right hand thread?
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http://forums.pelicanparts.com/uploa...1241493188.jpg |
it is a lousy closeup - but maybe this will help
http://forums.pelicanparts.com/uploa...1241532932.jpg |
Had time to work on the car these last few days and got the camber boxes done. I had a job going out to a laser cutting outfit not far some from me and had him cut a cad sketch we made up.
http://forums.pelicanparts.com/uploa...1242609362.jpg Used 3/16 cold rolled, very stiff. Had to cut half the thickness to be able to bend in the break... Welded the seam up after. Toke many precautions to square everything up during assembly and mostly install. http://forums.pelicanparts.com/uploa...1242609932.jpg http://forums.pelicanparts.com/uploa...1242609982.jpg Now its all tacked in, going to weld it up in the next few days and make the lift forks. Then its a couple weeks till I start on the cage. http://forums.pelicanparts.com/uploa...1242610283.jpg |
they look great, nice job!
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Thanks Chris,
I stumbled on your 3.6 - 3.8 thread yesterday... Outstanding read! You still have that motor? What was your final impressions after proper break in and map? As hot as you expected it to be...!?! |
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Well after a very busy summer between a double lower back hernia, knee surgery (ACL replacement and menisectomie) and getting married to the best woman in the world, work has resummed on my project... Here are some pictures and details!
Motor arrived and conversion done! 964 3.6 / RS single pulley conversion / light weight crank pulley / ps block-off and all uneeded stuff removed! Headers arrived yesterday, pictures to follow... http://forums.pelicanparts.com/uploa...1258140553.jpg Decided I wanted to build my own tube bender. Got great plans online, fun build and super machine!! http://forums.pelicanparts.com/uploa...1258140737.jpg Finally cage work started... http://forums.pelicanparts.com/uploa...1258140806.jpg http://forums.pelicanparts.com/uploa...1258140826.jpg http://forums.pelicanparts.com/uploa...1258140845.jpg Should be done with the cage in a couple weeks. After that car is going on the rotisserie to finish welding and removal of the undercoating. Suspension is ordered and I'll start getting parts shortly. Everything is coming from Clint at RebelRacing, this guy is the best! Cant wait to get my parts in.... More to follow... Oh and there is the wife! http://forums.pelicanparts.com/uploa...1258141502.jpg |
Congrats on the car progress! Err - and the wedding bit as well :)
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Looks like a great job!
Which tubing bender plans did you use? I don't find anything that looks like yours, and I'd like to build one too, can you post a link? Keep up the great work, and keep the pics coming! Jason |
Hey Jason,
You can find the plans here: Tube_Bender The guy is really nice and the plans are complete, easy to read and build from... I purchased the air/hydro cylinder from Ebay, if you are in the states you can find it at HaborFreight. I had to put in quite a few hours to build but the end result is very nice. Definitely better then a manuel ratchet bender. I'll probably get some more work done tomorow and post some pics... Thanks |
Thanks!
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Here are some more pics of the progress on the cage system. Driver door bars, front diagonal and harness bar left. Sunday is welding day!!
IPhone pictures, sorry for the quality... http://forums.pelicanparts.com/uploa...1259871737.jpg http://forums.pelicanparts.com/uploa...1259871791.jpg http://forums.pelicanparts.com/uploa...1259871807.jpg http://forums.pelicanparts.com/uploa...1259871858.jpg |
RSR Rear Tower Gussets
Congrats on your marriage! Good thing your wife already knows about your 911 hobby.
Regarding RSR rear tower gussets, do you have a drawing for these? I'd like to install a set. Thanks. |
Hi Mike,
I have no drawing of those gussets... I just used a piece of cardboad to make a 2D template. Put it on a 1/8 steel sheet, traced the outline then mirrored the other side, leaving about 1inch in between then bent the plate. I found it important to go all the way to the inner wheel well to cover the two section of the unibody for reinforcement. Same thing for the top part to clip over the strut tower cap. http://forums.pelicanparts.com/uploa...1259886236.jpg P.S.: I dont exactly pratice full disclosure with my wife of the costs related to the build of this car or any other racing for that matter... :D But she loves to tag along at the track and watch me work in the garage! Thanks |
Well cage is done! Didnt have time to weld it all in but finished all bars... Door bars will not be welded in until the end, makes access to the inside much to restrictive. There is still alot of things to get done!
http://forums.pelicanparts.com/uploa...1260201233.jpg http://forums.pelicanparts.com/uploa...1260201249.jpg http://forums.pelicanparts.com/uploa...1260201284.jpg http://forums.pelicanparts.com/uploa...1260201308.jpg http://forums.pelicanparts.com/uploa...1260201340.jpg I ordered a set of dimple dies to fab some nice tabs to attach cage and tub. Front A-arms, crossmember and rear trailing arms should be back from sandblast and powder coat this week or early next week. Should be just in time for front bushings and rear monoballs ordered from RebelRacing. |
It looks great.
I will offer tidbit of info since I'm dealing with fiberglass from GT Racing. I have both Getty and Gt Racing fiberglass going on my car. Stick with Getty's fiberglass parts if you can. They are sooooooooo much better than the Gt Racing stuff. The Getty fit and finish is much better. |
"I ordered a set of dimple dies to fab some nice tabs to attach cage and tub."
Where are you going to get these and what are you using as a press/device for the dimples? I was looking for something similiar to attach my roll bar to my B-Pillars - never really found anything... Would be interested in knowing what you come up with - nice looking cage btw. |
Plavan,
Thanks for the heads up... Not the first time I hear that comment, actually spoke to Hank at GT. Didnt leave me with the impression he wanted to do business. I have some parts I'll try to make work for now. Not really in to looks, just fast!! nolift, I found an outfit out of Texas on Ebay with some nice pieces and went with them. Did some research and found some good comments on their stuff. Havent received them yet but looking forward to it. They had two models, some in 4140 heat treated and some in 1018 annealed. Went with the 1018 set, for the amount of work I'll be putting these thru, should last a long time. I chose the option with setup bolt that requiers drilling and could be used with an impact gun. Should be fine for something like 18g, apparently up to 1/8th should be ok... Just search in ebay, should come right up! |
Just received front A-arm bushing kit and rear monoballs from RebelRacing!
These things are spectacular, if anyone needs please call Clint and order up a set. Fit is outstanding with zero play and flawless A-arm articulation. Bushings should last a lifetime with no need for lubrification. Going to take some time off for the holidays and keep you all posted on the progress in the new year... All the best! http://forums.pelicanparts.com/uploa...1261089111.jpg http://forums.pelicanparts.com/uploa...1261089474.jpg |
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Interested in your feedback on these as I have been thinking about doing these. Phillip |
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So the fronts are bronze/steel bearings with grease fittings- like PolyBronze but without the polyurethane?
Looks race-ready. :) |
The inner race is electro-polished ss riding on a teflon impregnated thermoplastic polymer bushing. No grease nipple and no maintenance just stiffness!
Like Flieger said they are race ready! Couldnt help myself, I test fitted everything last night and its really nice... No affiliation, just a very happy customer... Thanks Clint! |
Well I`m long over due for an update!
With spring now here the major work has resumed. All suspension parts are back form powder coating and look great. I bonded the inner races on the front a-arms, crossmember is like new now. http://forums.pelicanparts.com/uploa...1269032605.jpg http://forums.pelicanparts.com/uploa...1269032631.jpg http://forums.pelicanparts.com/uploa...1269032668.jpg Cage is all welded up except for door bars that will be last, need to have proper access to finish everything up. Finally finished the rottiserie!! Let me say to anyone that hasnt worked on a car like this before... Its the ONLY way to do it! I love this thing. I didnt put much engineering in to it, just a few scrap pieces of steel with 2 x 750lbs engine stands. I`m gona race the car, not the rottiserie so it was built to work, no frills. http://forums.pelicanparts.com/uploa...1269033061.jpg http://forums.pelicanparts.com/uploa...1269033105.jpg http://forums.pelicanparts.com/uploa...1269033136.jpg http://forums.pelicanparts.com/uploa...1269033206.jpg Will need a couple more days to remove the undercoating, then its off to primer. I`m mecanicaly stripping it with a 5inch grinder and coarse wire wheel. Works very well but alotttt of dust, best done outside! Transmission also arrived but not yet touched it. 74` mag 915 7/31 r&p pics to follow Trans. was in a running car with 100k, going to open inspect and reseal... I know, I know, 7/31 with a 3.6 is supposedly suicide but this is track only and was purchased as a crash box. Will go out only 10-15 times this summer and will be overhauled next winter. Just want to shake down and run in testing, rebuild is not in the budget this year. If anyone has a lightweight conversion flywheel w/DME ring kicking around, I`m interested. Also a reinforced diff cover will be needed... After discussing with a few tranny masters, I`ve deemed it safe to weld the spyders and get a cheap spool! I know this might raise a few eyebrows but its been recommended by people that have done this before. We did this all the time on VW way back when with no issue even with 300+hp. Easy on first gear.........lol lets see what happens! Clint at RebelRacing finished my Bilstein coilovers and they are ready to ship, just waiting on his torsion tube reinforcement plates to be ready. http://forums.pelicanparts.com/uploa...1269034543.jpg Rear shocks will be single adjustable and fronts fixed. 600lbs/f - 800lbs/r shocks valved to match I`ll get some more pics of the suspension up this weekend! Regards, Carl |
Nice work and thanks for the update. I like the reinforcement of the outer torsion tube cover attachment. Is that 1/8" steel plate reinforcing?
Thanks, Marc |
"Marc, I havent seen the plates yet as Clint is having them cut. I assume they'll be about 1/8 no more. I'll let you guys know when they arrive..."
More pictures and updates... Finally finished removing the under coating. Painstaking job but clean, nice to work on a bare chassis and free speed... http://forums.pelicanparts.com/uploa...1269882311.jpg Final cage bars installed and welded. http://forums.pelicanparts.com/uploa...1269882442.jpg http://forums.pelicanparts.com/uploa...1269883776.jpg I followed some good advice and notched out the floor for easy engine and tranny drop. Should make trackside removals quite easy. I'm making some tabs on the cut out piece that will attach it to the tub. Will post pics once done. http://forums.pelicanparts.com/uploa...1269884023.jpg http://forums.pelicanparts.com/uploa...1269884062.jpg Rolled chassis joint to allow for more clearence of CVs. Shocks are short travel, I should not have to cut in the tub. http://forums.pelicanparts.com/uploa...1269884213.jpg Installed spherical trailing arm bearings and dry fitted to camber boxes that needed some fine tuning. http://forums.pelicanparts.com/uploa...1269884363.jpg http://forums.pelicanparts.com/uploa...1269884408.jpg http://forums.pelicanparts.com/uploa...1269884438.jpg cont.. |
So ruff tub work is DONE, she is of to the bodyshop for primer and final paint on the underside. Chassis will be done in GrandPrix White, panels will probably be Gulf blue.
http://forums.pelicanparts.com/uploa...1269884712.jpg http://forums.pelicanparts.com/uploa...1269884745.jpg Some of the parts, rebuilt painted and ready to be bolted. Will be ordering some more stuff this month. http://forums.pelicanparts.com/uploa...1269884855.jpg http://forums.pelicanparts.com/uploa...1269884878.jpg I'll be using these few free days to clean up the tranny, insp. and reseal and get some odds and end sorted. Will get you some pics when she get back! Regards, Carl |
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