Hey Doug,
You are doing a hell of a job there. What kind of undercoating are you using and what seam sealer? Keep up the good work. Thanks

Hey I wouldn't be Yawning! Great story and thanks for sharing

To answer some questions...
 

I did not replace the floor pan(s), but there were times when I was thinking it might be worth it because of all the areas that needed work/had been worked on before. In the end, I just pushed through since I didn't want to head down that slope. Rockers were very solid... probably been replaced once before already. I am pleased with the end result right now, we'll see in 10 years!

I am just using the Wurth High Build U/C in the spray can. Except for in a few places, the integrity of the undercoating was pretty good. But with all my repairs, and the previous ones, I was not going to attempt to "unify" the look by making the texture all match. Really just want it protected. When I shot the front pan on the bottom, I liked how it went on and the sheen it has... so I decided to just use it as my "black paint" for everything on the bottom. I am planning to shoot the insides of the front fenders and both bumpers with the stuff when the time comes... all fiberglass parts, of course!

The seam seal is a FLAPS product... 3M's Dynatron. Comes in a caulking tube, ends up on your fingers (and the car). Right or wrong, that's what is on there; no going back now...

In reference to my thread title... like I said at the beginning, I have had the car for 2 years and I had wanted to start a build thread for a while. In the meantime Lars/speedo, Neilsen, Matt Cooley, etc. were busy posting their SWB builds and I thought to myself, "shoot, lots of folks are doing these cars... it may be old news/boring by the time I get around to posting my build".

Silly me... you folks never get tired of this stuff (and neither do I).

More work out back...
 

Spent a lot of time this week working in the engine bay. Here are some highlights:

- Installed the engine sound pad (911-556-891-01-M260 from our host) using 3M Super Weatherstrip and Gasket Glue. Buy 2 tubes... I used up one yellow tube, wished I had used black, so I bought black to finish up the edges.

- Installed the engine bay perimeter seal. Thought it might put up a fight, but it took less than an hour to get it all in. New/soft rubber is refreshing to work with...

- Installed OEM "Sport" motor mounts.

- Started the fuel system build up (more on that later).

Some pics:

http://forums.pelicanparts.com/uploa...1264861483.jpg

http://forums.pelicanparts.com/uploa...1264861511.jpg

http://forums.pelicanparts.com/uploa...1264861530.jpg

One other job that got done: A cool thing happens on the early cars when you decide to go with an upgraded ignition system and install an alternator w/ a built-in voltage regulator... there is not much stuff to mount on the LHS of the engine bay! The MSD and coil were the ones that came with the car and seemed like a good choice, so I kept them and made a custom panel to support them.

Back when I was cleaning up the engine bay areas, I used a template I made from a 71 panel to help spot in the mounting holes, then moved to a template for the panel I wanted to make, and ultimately to a bare custom panel (1/16" thick alum sheet) that a buddy made for me since he had the material handy:

http://forums.pelicanparts.com/uploa...1264861996.jpg

Fit checked the bare panel:

http://forums.pelicanparts.com/uploa...1264862081.jpg

Looked okay, so I mounted the components:

http://forums.pelicanparts.com/uploa...1264862130.jpg

http://forums.pelicanparts.com/uploa...1264862149.jpg

and bolted it in place:

http://forums.pelicanparts.com/uploa...1264862182.jpg

I will terminate and clean up all the wiring after the motor goes in and I can make sure I got it all right.

Noice!!!!!!!!!!!!!!

Very NICE!!
Keep up the good work.
I want a ride when done!!!

Q

subscribed

nice

Looks great Doug. I need to get my rear in gear so I can catch up!
-Dave.

Well Done!

Fuel System Coming Together at Last…
 

I worked on a few other little things this week, but mostly I was gathering up the last few bits needed for the fuel system and installing as much as I could on the car. The main components are as follows:

1. New SC-style CIS gas tank
2. Carrera fuel pump
3. Added a return line to the tunnel (from a 71T)
4. Generic in-line fuel filter
5. PMO fuel pressure regulator (FPR)
6. Generic 50 psi 5/16” ID rubber fuel line

I think that means parts from all 911 generations from 65-89 are represented! Here is how it looks installed in the rear of the car:

http://forums.pelicanparts.com/uploa...1265501015.jpg http://forums.pelicanparts.com/uploa...1265501048.jpg
http://forums.pelicanparts.com/uploa...1265501085.jpg http://forums.pelicanparts.com/uploa...1265501113.jpg

And here is the stuff up front by the tank. The lines from the pump to the tunnel are always “fun”:

http://forums.pelicanparts.com/uploa...1265501259.jpg http://forums.pelicanparts.com/uploa...1265501284.jpg
http://forums.pelicanparts.com/uploa...1265501312.jpg

One little detail I forgot to add to the car before I sealed up the front was the L-bracket that is used to support the top isolator on the factory fuel pump bracket. I decided to make a custom one using pipe strapping that hooks back to the aluminum cross member. Nice and tight fit, so it should do the trick:

http://forums.pelicanparts.com/uploa...1265501372.jpg http://forums.pelicanparts.com/uploa...1265501390.jpg

On a side note, I decided to use rivnuts to hold the FPR in place and thought folks might like to see the install steps. There were already two holes on the rear cross member that were centered on the engine bay, but I had to open them up to work with the M6 rivnuts I bought:

http://forums.pelicanparts.com/uploa...1265501634.jpg

continued...

Fuel System continued...
 

Here are the rivnuts and their installation tool:

http://forums.pelicanparts.com/uploa...1265501961.jpg

FWIW, I chose these rivnuts because of their ribbed shank and thin head height. They are cad-plated steel…

Rivnut being set in place, and one done:

http://forums.pelicanparts.com/uploa...1265501985.jpg http://forums.pelicanparts.com/uploa...1265502001.jpg

Two rivnuts and a custom aluminum L-bracket for the FPR. I installed the rivnuts “wet” with some black gasket goo just in case. Very solid mount.

Saved the best for last... the tank: :D

http://forums.pelicanparts.com/uploa...1265502093.jpg

New tank, modified by TRE, and painted/assembled by yours truly. Sorry guys, no through-the-hood filler on this R clone. Like I said for the '72 oil tank stuff, not going down that road...

I am pretty much ready to install the gas tank, just going to hold off a little until I do some more work up front. It is nice to be able to stand where the tank usually sits... great access under the cowl.

One less thing to worry about...
 

And this morning I took care of a nagging problem in the re-geared '68 902/02 tranny that will go in the car. For those of you that have gone through upgrading the simplified differential, you can relate with how nice it is to take this picture:

http://forums.pelicanparts.com/uploa...1265502793.jpg

MANY thanks to those on the site that documented this upgrade when they did it. Sure saved me a lot of time...

That's all for today. Enjoy!

nice & sanitary!

BTW - how much did that rivnut kit cost? and from where?

Rivnut Source
 

My Go-To for this kind of stuff is McMaster-Carr. A little more expensive, but worth it considering their inventory and cheap/fast shipping (I usually get their stuff next day for only $5). Anyway, to answer the question:

Installation Tool, M6, P/N 96349A764, $23.87
M6 Zinc-Plated Steel Rivnut 25 pack, P/N 95105A183, $8.82

I also grabbed some 97217A444 slotted body M6 rivnuts while I was at it... I figured they may work well on fiberglass if you back them up with a washer (assuming you can get to the backside). I am thinking license plate mounts, bumper braces, etc.

Hope that helps.

DITTO! I do the same. Rivnuts work great. My tool is a bit different, but end result similar. I may start using some sealer goup. Hadn't thought of that. In the American sizes, McMaster has a rivnut with an integrated seal on the backside.

Doug

Busy Month...
 

Time flies! It took a while for a number of things to gel over the last month (making/painting brackets, laying out stuff and selecting parts, waiting for them to show up). You know the drill... let's see if I can get the thread caught up.

Fuel Tank Installed

Spot all ready:
http://forums.pelicanparts.com/uploa...1267920247.jpg

In place:
http://forums.pelicanparts.com/uploa...1267920295.jpg

Some fit checking:
http://forums.pelicanparts.com/uploa...1267920363.jpg

And bottomside hookups complete:
http://forums.pelicanparts.com/uploa...1267920403.jpg

Went pretty smooth, just took some time to make sure it was positioned well before pinning it down.

Looking great Doug.... I wish I could show that kind of progress on some of my projects. Congratulations!!!

It should be easier to breath...
 

For some reason, the oil tank breather and the gas tank breather set-ups have taken me a LOT longer to sort out than I thought they would. So, I will do a bunch of pictures and try to articulate why I chose to do what I did.

First up, the oil tank breather...

After way too much time searching, this is the tank I settled on. $80 for something like this seems real cheap to me, so this was a "buy" versus a "make". The part number for the tank is STF-5116:

http://forums.pelicanparts.com/uploa...1267924439.jpg http://forums.pelicanparts.com/uploa...1267924397.jpg

In this case, size did matter to me (both overall and the fittings). I had a couple locations in mind for it in the engine bay (outboard of the RHS rear shock mount or on the RHS wall ahead of the oil tank). Both spots would be a tight fit and the ~1" ID hose coming off the oil tank is pretty big (for good reason, of course). I didn't want a bunch of adapter fittings in the set-up and my preference for the location was just ahead of the main oil tank on the RHS... wanted to use that factory S-hose if I could, too. So, the 5116 fit the bill regarding size and fitting location/size... what finally made it work for me was that it came with a -12 AN fitting on it. Just so happens the OD of the male threads on a -12 AN fitting are 1.0625"... nice for that 1" ID line!

So, here are the parts that will get installed and the gear to pull it off:

http://forums.pelicanparts.com/uploa...1267924979.jpg http://forums.pelicanparts.com/uploa...1267925007.jpg

(Like that donor bracket... license plate bracket from a trailer IIRC... should be able to get a couple parts out of that!)

Here is where I want it to be:

http://forums.pelicanparts.com/uploa...1267925186.jpg

Rivnuts to the rescue again:

http://forums.pelicanparts.com/uploa...1267925223.jpg

Support bracket made, painted, and in place:

http://forums.pelicanparts.com/uploa...1267925290.jpg

And everything installed: :D

http://forums.pelicanparts.com/uploa...1267925333.jpg

FYI, that S-hose is part number 911.107.393.01 (usually used to go from the oil tank to the RHS of a CIS air box).

REALLY glad that is done. Options down the road would be to add lines from the breather tank to the carb air filters to burn off the oil fumes (hope I don't smell them in the car with the heater on like I have read about) or mod the -12 AN fitting if I get a leak where the S-hose hooks up to those threads. All possible since the tank was made of uncoated aluminum and I have a friend that is good with aluminum welding. Those were 2 other reasons I went with that tank...

Hope that saves somebody some time!

Loving the gas tank!


Phillip