Who knows when, or if I'll be back.

I still have the car (that I rebuilt after my disaster at The Glen) but I'm broke and pretty much out of work. I'm sort of planning to do our local race at High Plains this summer but the days of eight races a year all over the country are gone for now.

I'd love to race with you again and will never forget the hard time you gave me in 2001 in Pueblo and CA speedway. Remember my botched start? You were truly brutal to me! Nor will I forget the help you've given me at the track.

Kind regards,

Jesse

http://forums.pelicanparts.com/uploa...1306556569.jpg
http://forums.pelicanparts.com/uploa...1306556589.jpghttp://forums.pelicanparts.com/uploa...1306556717.jpg

I know what you mean by hard times. My business has been going down hill for ten years. I;ve been down to only two races year for several years now. That is why I'm trying to break into the Porsche business to spite the lacking economy and other shops folding. A racer once told me many years ago that if something is important enough you will find a way. Actually, I think that was Kevin Buckler in 1996.

I remember Pueblo well. That was one of the great moments in racing history and I still tell that story for laughs today. I hope I wasn't too brutal. I think I was more confused than anything how a driver with your talent didn't know how to lead a start.

The only thing I remember about Cal-Speedway was the 3 Cup cars that tried to pass me going into the chicane. That was a real bad idea at those speeds and probably one of the scariest moments in my life. Had I not pulled off a brilliant plan B there would have been a very expensive mess to clean up. I was shaking for hours after that.

Just keep your head up Jesse and keep working at it. Things will eventually come around and we can have some more good times at the track.

BTW: Great pictures of the car.

Forgot to mention: I also scored a pretty nice dashboard this week which I needed badly.

This week I was a little less motivated that I should have been. I guess I'm a little burnt out. I did get the oil lines back on the turbo. I also removed the rear sway bar brackets from MS and welded on the new ones. I was hoping to get the front ones done as well but didn't get that far.

http://forums.pelicanparts.com/uploa...1307197095.jpg
Cutting the old brackets off is not a big deal. You have to be careful because the brackets are only welded to sheet metal.

http://forums.pelicanparts.com/uploa...1307197278.jpg
Contrary to the instructions I opted to cut off the entire bracket. In retrospect following the instructions may be a better way, but I didn't like the idea of butchering the original brackets and leaving part of it on the car.


http://forums.pelicanparts.com/uploa...1307197450.jpg
One thing I never noticed is that the brackets actually sit on a partially raised pedestal. This is because the frame member is not exactly parallel to the car.


http://forums.pelicanparts.com/uploa...1307198441.jpg
Getting the brackets tacked into position was one of the biggest challenges. Would have been allot easier with an extra set of hands. I thought I could hold it by tying it to the torsion tube, but that really doesn't work.



http://forums.pelicanparts.com/uploa...1307198707.jpg
This gap is why the instructions say to leave 1/16" of the old bracket. A little filler is no big deal though. Notice the transmission bracket in place to insure proper alignment of the bar.

http://forums.pelicanparts.com/uploa...1307198888.jpg

http://forums.pelicanparts.com/uploa...1307198971.jpg
THis is about all the welding that can be done on the bracket. No weld on te back side because of the raised pedestal. It would probably be better to bore a 2" hole in the bracket so it can be welded directly flat on the pedestal. It will hold well enough though. One of the bigger mistakes I made was thinking I had cleand the welding area well enough. I had forgotten about the galvanizing and the MIG doesn't like to weld to that stuff.


Next week:
Install oil tank, cooler, sound pad, and motor mounts on turbo.
New radiator, timing belt, rollers and front seals on 924S
Possibly build 2.4 race motor if crank gets back.
Oil change on Boxster

Then if I have time:
Wurth undercoat on sway bar brackets.
Install front sway bar reinforcements.
Roll cage mounting plates.

To spite the fact that I took extra time off last week I still only got a couple hours work done on the race car. But I did get done what I planned on.

I also got the 924S fixed, which was 10 plus hours. A few hours done on the turbo, and a few hours on the race motor(s). Actually ran into another disaster on the race motor. Wrist pin clips were wrong so I had to order ones from JE, and that was a bit of a challenge since the pistons were so old they were not marked, so not even JE knew the type of clip needed. On top of that the cylinders were not manufactured correctly and did not fit into the heads. My regular machinist was out of town so I had use my friend's lathe and machine the cylinders myself.

One oft he 2.4l race motors I'm working on.
http://forums.pelicanparts.com/uploa...1308205522.jpg

Installing the sway bar and reinforcements.

First I centered the bearing bracket and marked the holes. Notice n the right side, nest the bolt hole, there is a weld line running vertically. This becomes important later.
http://forums.pelicanparts.com/uploa...1308205649.jpg

First I drilled the bolt holes and and used pins to align the bracket and drill the thru hole with a 1-3/4" hole saw.
http://forums.pelicanparts.com/uploa...1308205912.jpg

Test fitting the alignment of the bolt holes.
http://forums.pelicanparts.com/uploa...1308206045.jpg

Next I had prep the area from the inside before I could weld in the new reinforcements. Buckley racing suggests that you don't have to weld in the brackets but I think welding them in is a better idea. Note on the right side of the stand-off area there is a weld. I found this weld on both sides, and on the drivers side it actually would interfere with any mounting bracket or backing plate. SO the weld had to be ground off to ensure flush mounting of the bracket. This is probably part of the reason why these brackets come loose. I have yet to figure out why the factory even put a weld there.
http://forums.pelicanparts.com/uploa...1308206505.jpg

The the Buckley reinforcement bracket welded in place. From here I just used the pre-drilled holes in the body to pilot hole in the new reinforcements.
http://forums.pelicanparts.com/uploa...1308206574.jpg

I cleaned off the undercoating because I believe the compressibility of the undercoating is another reason these brackets come loose. Again, note the weld on the right side of the bolt holes which also had to be ground off so the bracket could fit flush.
http://forums.pelicanparts.com/uploa...1308206680.jpg

The finished product primed to prevent rust till I can get paint on it.
http://forums.pelicanparts.com/uploa...1308207098.jpg


Next is to remove all the unnecessary brackets to reduce weight and to un-sunroof the car. Not looking forward to that...

Got a few more hours time on the car this week and it pretty much went off as scheduled.

No work on the race motor(s) because of a problem and waiting on parts, but I did get a few hours on the turbo. Fixed a couple more oil lines and wiring as well as pressure washing the engine compartment and installing a new sound pad and other parts.

Onto the sunroof delete:

http://forums.pelicanparts.com/uploa...1308516906.jpg
http://forums.pelicanparts.com/uploa...1308516950.jpg
http://forums.pelicanparts.com/uploa...1308517018.jpg

First task was to remove mechanical portion and the actual sunroof. Having never worked on sunroof in the past I decided to read up on the subject. The book was was wrong.


http://forums.pelicanparts.com/uploa...1308517181.jpg
http://forums.pelicanparts.com/uploa...1308517246.jpg

Next I had to remove the supporting brackets which involved drilling the spot welds on some brackets and cutting off other brackets.


http://forums.pelicanparts.com/uploa...1308517411.jpg

I then used a torch to release the sealant on the latter half of the structure. The sealant doesn't require allot of heat to come loose.

http://forums.pelicanparts.com/uploa...1308517552.jpg
http://forums.pelicanparts.com/uploa...1308517685.jpg

Since the roof is actually spot welded and crimped to the inner structure is basically has to cut out. You have to be careful to cut far enough back to get past the crimp line.

http://forums.pelicanparts.com/uploa...1308517858.jpg

In addition to removing all the useless interior brackets I also need to remove the seat rails because I have custom brackets for the seats and the factory brackets get in the way. Previously I carefully removed these brackets by drilling out the spot welds (about 50 for each side) so I could save the brackets, but this time I decided I would just cut and grind which I think is working out better. But at this point I ran out of cut off wheels so I'll have to get back to it next week.

So next week I need to finish removing the seat brackets and get started on making the replacement roof panel. I should also be getting started on fabricating the roll cage.

Can't believe its Wednesday already. This weekend I was up against a deadline to finish a race motor for a customer but I did manage to squeeze a few hours in on the race car. I finished removing the seat brackets and decided to I need to get the interior tip-top before installing the cage. Since PCA club racing rules now allow the complete removal of the interior in stock classes, the caveat is that the interior was be finished as nicely as the exterior. I found some rust under the rear seats that I didn't think was a big deal, but after hitting it with he angle grinder I can see its much worse. The only way to fix it so the rust doesn't reappear is is to sandblast it. I was trying to avoid sand because its hard to get back out of all the nooks and crannys and is generally a PITA. But I'm out of sand so that will have to wait till I can order more.

http://forums.pelicanparts.com/uploa...1309365597.jpg
http://forums.pelicanparts.com/uploa...1309365818.jpg

James,

I trust you didn’t forget this nut (red circle) late at night. :eek:

http://forums.pelicanparts.com/uploa...1309366638.jpg

Looks very nice.

Best,
Grady

Probably not

http://forums.pelicanparts.com/uploa...1309371000.jpg


But I can't recall why it would not have been installed for the other photo.

Tom,

I bet you know Kim Nakashima! He is a good friend of mine from my motorcycle racing days with the AFM in Northern California.

Scott

Nice work James
When you are ready for graphics, we digitized the whole package and its available as a wrap from us. Makes for a much easier install and longevity. Check out this client's car that was in process.

http://forums.pelicanparts.com/uploa...1309378292.jpg

You suck Dave! (LOL) Your exactly the guy I'm looking for. I thought about doing a wrap for obvious reasons but though it would end up being as much work in the end as just painting. But I loth having to do that much paint work on my time budget; and since you have it done already... Shoot me a PM with price and more picts.

Oh, and can you convert the graphics for a short hood car?

Yup I sure do know Kim! Very good rider(almost as good as me:D)

Weekly update:

Due to the holiday I got a few extra hours to work on the car. Nothing exciting, but it all has to be done and it all takes time.

Pretty much finished the turbo motor. Just waiting on a hose from Germanay, a piece of sheet metal trim, and the shocks to get back from Bilstien; then I should be able to instal the motor and try to get it running.
http://forums.pelicanparts.com/uploa...1310016061.jpg


I didn't want to do any sandblasting the car but there was too much rust in the back seats not to. The rust was bad enough I had a few pin holes after the blasting. Now that I have the area clean I basically have to do the bodywork and bring it back to the original finish. I ran out of filler and sand paper and due to the holiday I couldn't get more so I'll try to finish next week.
http://forums.pelicanparts.com/uploa...1310016309.jpg



I had to clean the glue out of the door seal channels. I use a lacquer soaked rags to softer the glue and it usually wipes right off (depending on the glue). You have to be careful doing this because paints don't like lacquer thinner and you might unintentionally remove the paint.

http://forums.pelicanparts.com/uploa...1310016685.jpg
http://forums.pelicanparts.com/uploa...1310016711.jpg


While using the lacquer thinner I realized how soft the tar undercoat mats on the floor are. I was just going to leave the undercoat on the floor because I need the weight, but I don't think there will be a good reaction when I paint so now I have to remove all the undercoat.

I also got the second Carrera-Panamerica motor back this week from Ollie's so I'll be getting started on that when a few more parts come in. This was the motor when I first got it.
http://forums.pelicanparts.com/uploa...1310017253.jpg

Very nice james.. that turbo engine looks like it needs to be in a Ga car :)

Wish it were mine...

Due to last weeks holiday, this week was short and I didn't get any time to work on the car.

I did manage to score this RSR style passenger seat. I just need to get it upholstered. I'm also thinking about making replicas if anybody is interested.

http://forums.pelicanparts.com/uploa...1310761626.jpg


This is the car I built the last motor for.
http://forums.pelicanparts.com/uploa...1310761729.jpg


This is the car I'm building the current motor for.
http://forums.pelicanparts.com/uploa...1310761756.jpg

Since the turbo and race motor are on hold I got a little extra time to work on my stuff. The nice thing about documenting a build is you can look back and remember all the work you put into a project. I have forgotten most everything I did over the years on the old race car.


Removing the tar floor mat isn't particularly hard, but everything is a PITA when its 100+ degrees with humidity. But it still has to be done.


http://forums.pelicanparts.com/uploa...1311276625.jpg
http://forums.pelicanparts.com/uploa...1311276669.jpg

Monday I went over and cut the roof section out of another 911 and fitted it to the race car. Now its ready for welding.
http://forums.pelicanparts.com/uploa...1311276724.jpg

Made the first section of roll cage. This is the first time I have attempted this from scratch. Normally I start with a kit but what I needed was not available. This is actually a pretty tricky process because every mandrel starts its bend at a different spot and due to spring-back and other issues its slightly less than a precision process. There was allot of trial fitting to be sure we didn't over bend anything. Now its pretty much perfect with less than a 1/4 gap on the B-pillars. The first bar I made was an inch narrow so I had to start with a new section. Not cheap at $8 per foot for tubing, but I will salvage what I can for other sections.
http://forums.pelicanparts.com/uploa...1311277292.jpg


Made a few of the feet for the cage.

http://forums.pelicanparts.com/uploa...1311277537.jpg