993 c2 rsr clone build - photo intensive

[Thatcher]

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:





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.











Val's car with my M3 parked under it:

[Thatcher]

cage masked off and ready for paint:



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.







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

[Thatcher]

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



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



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



sanded to 400 and ready for primer:




can't get paint on the adidas!



and finally, base & clear:







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

edit: updates on the bottom of this page

[village idiot]

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

[Talewinds]

Oh man, so cool! Please keep us updated!

[e3photo]

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

Cheers,
Emerald

[Kroggers]

Originally Posted by e3photo

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

Cheers,
Emerald

+1

[spence88mph]

awesome, thanks for sharing!

[onboost]

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

[78SCRSMAN]

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. Nice project too... Sub'd

[Cory M]

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

[Thatcher]

Thanks guys

Originally Posted by e3photo

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

Cheers,
Emerald

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.

Originally Posted by onboost

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

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.

Originally Posted by 78SCRSMAN

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. Nice project too... Sub'd

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!

[e3photo]

Thanks Thatcher,

I want to do the bumperette delete on my 993

I'll have to give it a try.

Cheers,
Emerald

[Thatcher]

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



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.



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.



(colin):




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?



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





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.

[crashmy911]

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

[slow&rusty]

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

Yasin

[Griffinroydonal]

Thats a million dollar wheel collection !

[baq911]

Subscribed! awesome dream build man.

[Flieger]

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?

[Kroggers]

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?