Yawn… Yet another 911R Clone build thread…

[R_Builder]

But had to deal with my dash top first. The original pressboard dash piece I had was in decent shape but shrank too much with age to fit well, so I decided to make a new one out of fiberglass. Too bad I had already wrapped the pressboard version in new vinyl . So, rough cut to shape:



Lots of back and forth fitting and trimming, then finally drilled the holes and fit it with the plastic pins:



4 hours to get to that stage but very good results. I was able to get the vinyl off the pressboard and onto the fiberglass with the help of all those binder clips I seem to have laying around now. It was like headliner work all over again:



And installed:





The windshield was all set to go with a factory seal and new trim, so after a couple false starts my son and I got it installed for good without too much drama.



Sweeeet!!!

[merbesfield]

Great work and great job narrating. Thx for the show.

Where did you source the sheet of fiberglass? How thick was it?

[R_Builder]

Originally Posted by merbesfield

Great work and great job narrating. Thx for the show.

Where did you source the sheet of fiberglass? How thick was it?

Made the f/g sheet myself as I have the resources readily available to do so .

It is about 1/8" thick (12 plies)...

[70basket]

Looking really good Doug. You two did a great job on the headliner.

[R_Builder]

Rear decklid is on for real now. Wired in and lights work. I am using a factory latch/release setup for "security" and a clean look:





Now I just need to get that darn rear bumper back on so I can final fit the rear tail light housings to complete the back end...

[R_Builder]

I am continuing with the interior work. I am not a big fan of the '68 break away interior rear view mirror, so early on I decided to go with a '65-'67 chrome mirror, which would require me to make an adapter plate. All good, except I forgot to do that before the headliner install! I am a little bummed about this as I missed the opportunity to hide it, but it is not too visible when all is said and done and I took the time to finish it off nicely:









That last shot is hard fought. You would think that installing the sun visors would be quick and easy, but anything that has me working with the fresh headliner is kind of tedious. But that should be the last time, so I am grateful for no slip ups!

If the exposed mirror adapter ends up bugging me, I didn't do anything to the headliner that would preclude me from going back to the '68 style mirror. Guess it can just be a conversation piece for those that look real close...

One more thing to take care of in the interior, then it will be time for carpet install.

[merbesfield]

Originally Posted by R_Builder

I am continuing with the interior work. I am not a big fan of the '68 break away interior rear view mirror, so early on I decided to go with a '65-'67 chrome mirror, which would require me to make an adapter plate. All good, except I forgot to do that before the headliner install! I am a little bummed about this as I missed the opportunity to hide it, but it is not too visible when all is said and done and I took the time to finish it off nicely:









That last shot is hard fought. You would think that installing the sun visors would be quick and easy, but anything that has me working with the fresh headliner is kind of tedious. But that should be the last time, so I am grateful for no slip ups!

If the exposed mirror adapter ends up bugging me, I didn't do anything to the headliner that would preclude me from going back to the '68 style mirror. Guess it can just be a conversation piece for those that look real close...

One more thing to take care of in the interior, then it will be time for carpet install.

My early mirror has an annoying vibration while driving. Anyone have any ideas how to stop this?

[jac1976]

R_Builder
Really enjoying following this project. I can be a bit OCD and perseverate details, so in regards to your headliner/rear view adapter conundrum I think it adds to the purpose-driven aesthetic of the R. Of course, not my car but just wanted to let you know that another guy out there who sweats similar issues thinks it fits the look.

[jac1976]

To further my point, the engineers could have likely found a way in which to hide the rear deck lid hinges whilst still allowing the lid to fully open. In the end, they sit atop the lid...and, come to think of it, have a similar look to your rear view adapter.

[R_Builder]

Originally Posted by merbesfield

My early mirror has an annoying vibration while driving. Anyone have any ideas how to stop this?

Only one joint that could be loose... and I suspect the glass has to be out to work with it . I have not crossed that bridge before (and hope I will not have to).

[R_Builder]

Originally Posted by jac1976

R_Builder
Really enjoying following this project. I can be a bit OCD and perseverate details, so in regards to your headliner/rear view adapter conundrum I think it adds to the purpose-driven aesthetic of the R. Of course, not my car but just wanted to let you know that another guy out there who sweats similar issues thinks it fits the look.

Thanks jac1976. Time will tell, but it serves the purpose for now and I can move on to the next steps!

[R_Builder]

Carpeting process is moving along nicely (but no pics to share yet). First step was to put a little soundproofing in the rear seat/parcel shelf area. This is the 1/8” thick, adhesive-backed stuff from Aircraft Spruce. Not too much to it but to do it:





This is all it will get. Not planning any science projects here. I guess I can always go back and add stuff to the floors pretty easily if need be, but that would be a different product for sure.

Weird to see it all get covered up after so long....

[merbesfield]

Originally Posted by R_Builder

Only one joint that could be loose... and I suspect the glass has to be out to work with it . I have not crossed that bridge before (and hope I will not have to).

It is not the glass. The entire mirror vibrates from the roof where it is mounted. I have tried tightening the screws. If you put your finger on it, it will stop.

[schnelltarga]

My 1970 MG Midget (I know, not the same type of engineering - but with the same wobble) made every headlight in the rear-view mirror look like the headlights were making circles. I made a rubber gasket the shape of the mirror mounting to absorb the vibration, and the world was stabilized. Try it, it just takes some material with the ability to have some cushioning.

[R_Builder]

See:



Oh wait, you probably don’t really want to see all the scraps ! How ‘bout this instead?









I used 3M spray 90 just about everywhere, but the floormats are just sitting in place for now. Just like the headliner, I must give most of credit to the wife for helping to make the carpet install successful. We make a good team on these types of jobs...

As you can see, there is more progress than just carpet since it all needed to be worked together. Roll bar went in finally (bought it from TRE a loooong time ago), everything around the pedals is closed out, the engine ECU is mounted for good, shifter and p-brake are in (with heater wire and handle throttle hooked up), seat brackets installed, and… sills/thresholds closed out:



I will probably spend a little more time fussing with the sills and lower door jamb areas to get the vinyl wraps and carpet strips looking better, but they are good for now.

Guess it is about time for some chairs, eh? If you look close, you can see that I have also started in on the last big assembly step… the doors. Lots of parts involved there, with fit checks, more upholstery work, seals galore, and fiddling with the door frames. More on all that stuff next time.

Take care,

[R_Builder]

As always, time flies.. but slow and steady progress this year. Looking back in my pictures, it looks like I moved back to the rear to rehang the bumper for good:



Then back up to the front to truly get the headlight buckets ready for the H4's (lots of trimming for a good fit, lower brackets, drains, safety zip-ties, etc.):





Then it was back to the doors. Finally got to hang these gems and install the roll up windows:





Like I have mentioned before, there is a lot of time spent getting all the door stuff working right and all the seals in place. But in the end, you finally get to put these on :



The outer trim and window swiper finish off the outside, and the car is finally all tight:



Took a little while to get up the nerve to drill into the door frames for the updated wind blocks, but all turned out just fine:



The proverbial light(s) at the end of the tunnel:

[Tim K]

Originally Posted by R_Builder

...
Took a little while to get up the nerve to drill into the door frames for the updated wind blocks, but all turned out just fine:



...

Doug, I always enjoy your updates. Keep up the good work.

What is this?

Tim

[andybullen]

Everything is so well done..... Really love the fuel lines, what kind are they?

[obscene]

awesome! thanks for sharing!

[R_Builder]

Originally Posted by Tim K

Doug, I always enjoy your updates. Keep up the good work.

What is this?

Tim

Thanks Tim!

"wind blocks" from our host's catalog:



They close up the gaps between the door shell sheetmetal and the window frames at the front and rear. Just something from the later cars that will work on the earlier cars...