993 c2 rsr clone build - photo intensive
 

I recently picked up my first 993: a Polar Silver '95 C2. I bought it as a project that my friend Roberto started almost a year ago. He had the interior gutted and had a cage welded in. He then bought a c2S turbo (he also owns a 997 gt3), and decided to sell the rsr project to me. I'll be receiving some help from Colin Taylor (Auto Sea Racing) and Ralph Meaney (Meaney Racing). I started working on the car in December, I'm hoping to have the body work and paint finished by mid Feb, and I should have the car on the road by March 1st.

Going onto the car:

- Kevlar / Carbon roof
- KW V3 coilovers
- walrod bushings
- tarett toe control arms
- tarett drop links
- RSR flares and front lip
- 993 ducktail
- Custom leather Recaro Pole Positions
- Schroth harnesses
- Leather RS door cards
- German RS carpet kit
- 18x9.5 18x11 3 piece twists
- 18x9 18x12 Fikse set

How the car looked when I took over the project:

http://i976.photobucket.com/albums/a...cup/993072.jpg

http://i976.photobucket.com/albums/a...p/993063-1.jpg

prepped the cage for awlgrip anti-corrosion sealer and did some test fitting with the flares and various width wheels. painted the cage with the sealer. prepped the cage again and painted two coats of awlgrip 545 primer.

http://i976.photobucket.com/albums/a...cup/993026.jpg

http://i976.photobucket.com/albums/a...cup/993027.jpg

http://i976.photobucket.com/albums/a...cup/993028.jpg

http://i976.photobucket.com/albums/a...p/993019-1.jpg

http://i976.photobucket.com/albums/a...cup/993021.jpg

Val's car with my M3 parked under it:
http://i976.photobucket.com/albums/a...cup/993019.jpg

http://i674.photobucket.com/albums/v...ultz/KB148.jpg

cage masked off and ready for paint:

http://i674.photobucket.com/albums/v...january072.jpg

picked up a scrap honda bumper from a body shop to cut up and make cutouts to plastic weld shut the bumperette holes and tow hook cover holes. VERY time consuming.. i was up till 11PM cutting and plastic welding.

http://i674.photobucket.com/albums/v...january080.jpg

http://i674.photobucket.com/albums/v...january084.jpg

http://i674.photobucket.com/albums/v...january082.jpg

Colin sprayed the cage, underside of the wing, and backsides of the doors:

http://i674.photobucket.com/albums/v...painted003.jpg

http://i674.photobucket.com/albums/v...painted005.jpg

i've been putting in early mornings (sometimes) and long nights to get this car finished in the near future, and it's paying off. seeing some good results so far.

ready for primer

http://i674.photobucket.com/albums/v...odywork009.jpg

awlgrip 545 primer plus awlgrip high build on the parts with bodywork

http://i674.photobucket.com/albums/v...odywork012.jpg

rolled the car outside for a bit to shuffle things around inside

http://i674.photobucket.com/albums/v...odywork017.jpg

sanded to 400 and ready for primer:
http://i674.photobucket.com/albums/v...odywork027.jpg

http://i674.photobucket.com/albums/v...odywork029.jpg

can't get paint on the adidas!

http://i674.photobucket.com/albums/v...odywork030.jpg

and finally, base & clear:

http://i674.photobucket.com/albums/v...odywork034.jpg

http://i674.photobucket.com/albums/v...odywork043.jpg

http://i674.photobucket.com/albums/v...odywork039.jpg

more updates coming soon! i'm building the kevlar / carbon roof this weekend.

edit: updates on the bottom of this page

Awesome looking project! Can't wait to see your progress:cool:

Oh man, so cool! Please keep us updated!

Looks great. Any more details on your plastic welding technique?

Cheers,
Emerald

+1 SmileWavy

awesome, thanks for sharing!

Thatcher..

Nice project man.. isn't that plastic welding fun?!

I may need to get with you on some wheel halves.. I'm looking to bump-out the outers on my SuperCups.

Thx,

Paul

Thatcher,
Good to hear Ralph Meaney is still around. He worked on my first Porsche, a 914, some 20 years ago. He must be fart'n dust by now. :D Nice project too... Sub'd

Nice! I'm knee deep in my own 993 widebody racecar project.


If you want to see a ton of 993 widebody racecar pictures check out my thread on Rennlist: Show me your 993 widebody pics! - Rennlist Discussion Forums

Thanks guys

Sure - plastic welding is pretty easy.
1. cut out the shape of plastic you want with an air saw or cutting shears so that the peice fits perfectly with hardly any gaps
2. grind away all paint in the area you are plastic welding
3. put on your respirator with vapor cartridges. if you don't have a respirator, i suggest doing the work outside with a fan blowing so that you don't inhale the plastic smoke.
4. with the tip of a soldering iron, cut in a "stitch pattern" along the seams.. in other words, stack an X, one on top of the other, all along the seam
5. go back and melt away the stitches with the flat part of the soldering iron, this will smooth out the seam and flatten it all out.
6. repeat steps 2-4 on the back side of the plastic.
7. once it's cooled down, take a grinder to the seams to make sure there are no high spots.
8. fill all the seams with a good plastic repair filler. In my case, I used awlgrip awlfair filler. You can then sand the filler and prime.
Hey thanks Paul - yes, plastic welding is kinda fun :)
Happy to help with your Supercups, I should have whatever width outers you need readily available.
Haha, yup ralph is still around. He has some great stories.. he's a good dude.

Cory M - yup, i've gone through every page of that thread a few times. definitely some cool stuff in there!

Thanks Thatcher,

I want to do the bumperette delete on my 993

I'll have to give it a try.

Cheers,
Emerald

update time..

my good friend Rob (Flipside Customs), welded the headlight squirter holes shut on my front fenders. if any of you guys need custom fab work done in the Seattle area, he's your guy.. he does amazing work. Welcome to Flipside

http://i674.photobucket.com/albums/v...lection059.jpg

waxed and masked off the roof on the early 911, then laid out the kevlar. I cut the kevlar an inch from the edge of the roof, then cut the carbon and carbon vail exactly to the edge on the sides, and past the edge on the front and back.

http://i674.photobucket.com/albums/v...lection060.jpg

colin and i laid up the roof earlier today. We wet out the first layer (kevlar), second layer (carbon), third layer (carbon vail), then peel ply. cures over night, i can release it tomorrow.

http://i674.photobucket.com/albums/v...lection078.jpg

(colin):
http://i674.photobucket.com/albums/v...lection080.jpg

http://i674.photobucket.com/albums/v...lection084.jpg

my plan was to build 18" Kinesis Supercups.. well i've changed directions on that. Decided to re-configure a set of 18" RH 3.6 turbo wheels that I had sitting around. Building them to be 18x9.5 18x11.5. still undecided about painting the centers a medium grey, or color matching them to the car (polar silver). thoughts?

http://i674.photobucket.com/albums/v...lection076.jpg

meanwhile, my wheel collection has been growing. it's been getting awfully hard to walk around my apartment..

http://i674.photobucket.com/albums/v...lection014.jpg

http://i674.photobucket.com/albums/v...lection012.jpg

Tomorrow i'll release the composite roof, trim it up, and fit it to the car. Everything is coming together; Ordered my seats from Recaro the other day, they will be finished in four weeks. KW V3's on the way from Germany, and various parts from Brad at BW Motorsports.

I'm more interested in the brunette in the white panties!!!!!!!!!!!!!!!!!

Wow...awesome build! Loving it. Congrats on great attention to detail and having talented buddies help out.

Yasin

Thats a million dollar wheel collection !:eek:

Subscribed! awesome dream build man.

I think your last three photos were too large or something. I cannot see them- just the boxes with the red X.

Is the Carrera 3.0 RSR yours as well?

We can not see the last three picture as they are hosted on the Rennlist forum and you need to to be a member to see the pictures. Would you mind posting them on the Pelican forum as well?

sorry about those pictures not working. just rehosted them.

here's the latest.. the KW V3's arrived from germany, and the kevlar carbon roof skin has been fitted to the car. I'm really happy with how it turned out.

http://i976.photobucket.com/albums/a...ar_roof002.jpg

http://i976.photobucket.com/albums/a...ar_roof004.jpg

http://i976.photobucket.com/albums/a...ar_roof008.jpg

:)

latest progress..

my friend bryce stopped in after work to help block sand the roof before primer
http://i35.photobucket.com/albums/d1.../random008.jpg

rob welded my hood squirters and emblem holes shut on the hood
http://i35.photobucket.com/albums/d1.../random015.jpg

http://i35.photobucket.com/albums/d1.../random016.jpg

545 primer
http://i35.photobucket.com/albums/d1.../random017.jpg

after 545, high build, and awlfair.. sanded up to 120 and ready for final coat of 545 primer
http://i35.photobucket.com/albums/d1.../random026.jpg

http://i35.photobucket.com/albums/d1.../random033.jpg

yellow stuff over areas with metal work = awlgrip anti-corrosive 30-Y-94 primer
white = awlgrip 545 primer
beige = awlgrip high build primer
red = awlgrip awlfair fairing compound

roof and quarter panel will get final coat of primer tomorrow, which i'll sand to 400 on Thursday/Friday. we'll be spraying color and clear over the weekend, i'll start putting everything back together next week :)

what's the projected weight of the finished car?

sub'd!

subb'y sub

Fun! :p

Sub'd Really Cool!

Still not showing up. Says to update to photobucket pro. Bandwidth has been exceeded.

okay update time..

had to do a repair on a giant crack in the RSCS front splitter that I got in on Friday. Repaired it that night and Saturday morning.. set me back a good 5 hours.. I had to grind down the crack, reinforce it with two layers of carbon on the back side, shape the front leading edge with thickened resin, sand it down, put on a coat of primer, and sand that down :mad:

http://i976.photobucket.com/albums/a..._silver020.jpg

http://i976.photobucket.com/albums/a..._silver028.jpg

Saturday was a long day. I was at the shop till 5AM getting everything ready. Went home for three hours of sleep, and got up at 8AM to keep going on the car.

http://i976.photobucket.com/albums/a..._silver032.jpg

http://i976.photobucket.com/albums/a..._silver041.jpg

http://i976.photobucket.com/albums/a..._silver044.jpg

http://i976.photobucket.com/albums/a...ilver050-1.jpg

Sprayed the car Sunday night. Was practically running on fumes at that point.. dead tired, and a bit nervous about painting the car. My painter had to prep for his trip to Mexico, so I ended up finishing the job myself. turned out pretty well though, especially being my first time spraying anything besides primer... and i suppose that's really the best way to learn.. just do it. I'm definitely happy with the results, and so relieved to be finished. now I can take my time putting it together and start enjoying the project. i'll wet sand and buff everything tomorrow.

http://i976.photobucket.com/albums/a..._silver062.jpg

http://i976.photobucket.com/albums/a..._silver063.jpg

http://i976.photobucket.com/albums/a..._silver064.jpg

http://i976.photobucket.com/albums/a..._silver065.jpg

http://i976.photobucket.com/albums/a..._silver066.jpg

http://i976.photobucket.com/albums/a..._silver073.jpg

http://i976.photobucket.com/albums/a..._silver075.jpg

Very impressive progress, well done.

Fun, fun, fun!

Are you going to stay with the C2 3.8 tail or go with a 993 tail?

The last several posts say "Photobucket Bandwidth exceeded" ...
http://i674.photobucket.com/albums/v...lection084.jpg

Weird, after I typed this they popped up!

staying with the 3.8 tail for now, although my preference would be the 993 supercup tail. if someone wanted to trade me, I would.

My seats arrived thanks to my good friends @ Recaro. We did leather Pole Positions with silver double top stitch, silver logo, and charcoal alcantara inserts.

I bolted on some of the body panels, cleaned and waxed all four wheel wells, and built a set of 18x9.5 18x11 three piece twists. I've also got a set of 18x10 18x12 Kinesis K28's with slicks coming, they should be here tomorrow. I still have the 18x9.5 18x11.5 RH 3.6 turbo wheels but I put them up for sale, the rear outer lips aren't wide enough for my car. Also building a set of 18x9.5 18x11 "Supertwists".. Supercups on one side of the car, 3 piece twists on the other side of the car, purple centers all around. Kinda different.

http://i35.photobucket.com/albums/d1...3_march008.jpg

http://i35.photobucket.com/albums/d1...3_march010.jpg

gross
http://i35.photobucket.com/albums/d1...3_march012.jpg

waxed and ready to rock
http://i35.photobucket.com/albums/d1...3_march014.jpg

http://i35.photobucket.com/albums/d1...3_march026.jpg

http://i35.photobucket.com/albums/d1...3_march034.jpg

http://i35.photobucket.com/albums/d1...3_march035.jpg

http://i35.photobucket.com/albums/d1...3_march052.jpg

they will suck in a good bit when the car is on the ground

http://i35.photobucket.com/albums/d1...3_march053.jpg

http://i35.photobucket.com/albums/d1...3_march040.jpg

Great thread and photos. Thanks for sharing.
I find these inspirational. It's great seeing someones dream come to life.

Well done young man!

great build,love those seats

Subscribed. Nice work on the roof.

A little late to the party but a crossbar in that roof section would have been a good idea. The CF roof panel offers no protection from rollover or intrusion. Car looks great.. congrats.