Another ST-build - this time from Denmark

[Danish Dynamite]

Originally Posted by cnielsen

Hey Christian, great work! I want to point out though that the sides of front bulk head should be on the inside of the lateral supports instead of wrapped around the outside of those like you show. It might affect the fit of the fenders and hood as you would have made the front of the car narrower than it should be.

Thanks, for the advice I know my body work guy has have everything lined up and mesured, so I guess this was the way it was more straight. I trust him on that call.

/Christian

[Craig_D]

Originally Posted by Danish Dynamite

You put a lot of work into it! And looks really good I have them same and more work to do on my suspension. Most of my parts are from Rebel Racing.

My body work guy is considering either to remanufacture rain gutters and weld them on the existing roof, or to replace the whole roof with one that has rain gutters. I want the original look back! I will go for a full cage at some point

Thanks Christian! This is my first 911, so I'm learning a lot and absolutely loving it! I'll watch with keen interest when you're onto the suspension bits. Are you sticking with torsion bars or going to coil overs?

Funny about the rain gutters...some people would give a lot to have them removed and you have the opposite problem! I understand though, you want to have the proper look for your ST conversion. Maybe a lightweight composite roof while you're re-applying the gutters.

[Danish Dynamite]

Originally Posted by Craig_D

Thanks Christian! This is my first 911, so I'm learning a lot and absolutely loving it! I'll watch with keen interest when you're onto the suspension bits. Are you sticking with torsion bars or going to coil overs?

Funny about the rain gutters...some people would give a lot to have them removed and you have the opposite problem! I understand though, you want to have the proper look for your ST conversion. Maybe a lightweight composite roof while you're re-applying the gutters.

This is not my first Porsche, but it is by far the one I have done most work on! Expensive but fun

I know! I wish someone closeby wanted a roof without rain gutters so we could swap A composite roof would be nice, but I have a roof on hand with rain gutters, so I might be using that.

[Danish Dynamite]

A little more info on the engine:
When I bought the car, the Swedes had made a mess of an engine. The original 2.4 liter engine block was gone. They had bought a new 3 liter Carrera block for the car, reused the crank, rods and heads. The had gotten Carrera pistons and cylinders. They had to drill new holes for the pins to make the heads fit, and machine them too. It never really worked. The engine was runing fine, when I bought the car, but when I got homw I could hear it was leaking air, so I decided to take it apart and rebuild it. I reused the cylinders and crank and the engine block. I got JE pistons 10.5 comp. Adjusted to 10.2. Carillo rods. Carrera 3.2 heads with new valves and guides. GE 60 cams. When I got the car it was fitted with the original MFI pump and throttle boddies, but with stacks from a 2.2S in magnesium.

I wanted to reuse that setup in my own engine build, but what I did not know was, that the Carrera 3.2 heads are lower towards the intake than 3.0 Carrera or any older heads, so there was no room to drill a hole for the injector. Also the throttle boddies on a 2.4S is a lot smaler than the intake port of a Carrera 3.2.

A friend of mine has a CNC machine, so he made these blocks for me:





They were fitted to the heads with small screws and the hole for the injector was drilled between the block and the head. It has worked fine for 4 seasons.

At the time the block was 42 mm on the side facing the head and 36 mm on the side facing the throttle boddies.

Now I have made them 42 mm on both sides, but retaining the profile suitable for the shape of the intake port.



More info on that in the next post...

[Danish Dynamite]

In this trim, with the "too small" throttle boddies, DANSK stainless steel heat exchangers and a DANSK sports muffler, the engine made 260hp at the flywheel, and it pulled really strong

Now that the car is apart, I wanted to upgrade on the exhaust side as well as the intake side. See above for the exhaust.

My dad had some throttle boddies on shelf that he had previously used on his race car, before going for high butterlies

The were 42 mm and the stacks were a lot larger too. The only problem was that the guides holding the pin for the function of the throttle were loose. So I had them sent to my machinst guy. He cleaned them up and replaced the guides. Now they work really well without any play. This is how they look:













Block testfitted:

[Danish Dynamite]

The velocity stacks that my dad had for his setup was a bit too small for the intake stacks, so I had some made in Germany:



The base was a lot higher than the original ones, so I had to take some material off in order to have enough room for the washer and nut. But they look really nice test fitted







Visually there is a difference to tell between the small, old setup and the big, new setup:

[Danish Dynamite]

But once messured there is a lot of difference:

Small, intake side: (Porsche was very precise )



Big, intake side:



Small, top of intake stack:



Big, top of intake stack:



Old and new velocity stacks:









I am really looking forward to seeing how much difference this and the new exhaust system change makes on the dyno! Any guesses?

[Danish Dynamite]

Cleaned with WD40 and Vaseline. Top and buttom assempled:











The flow looks pretty good

[giovanni86]

great build

[wayner]

Wow. I just found this for the first time.
Subscribed!

[Danish Dynamite]

I wish I didn't have "time" to do all stuff like this in the basement, now that the weather in Denmark is getting really nice. I would rather be driving...

I got a set of modified original adjustable spring plates from Rebel Racing along with their bushings. They were yellow plated, so I painted them to have a more subtle look:



Og course leaving the part for the sleeves unpainted:








I glued the sleeves on with stuff simular to JB Weld:







Testfitting the sexy bushings

[Danish Dynamite]

Back to the throttle boddies:

Pre fit:







Fun detail. The small rubber clamps holding the fuel lines are screwed directly into my old throttle boddies from 1972 but the pre 1972, that I am using now only have a little hole, so I had to find a very little nut to fit them:

[Danish Dynamite]

Fitting the air cleaners:







I had the top machined so they would be able to squirt fuel simular to the original aircleaner on a pre 1972 MFI setup

[Danish Dynamite]

Air cleaners fitted:

[Danish Dynamite]

Work on the body continues. We found a donor car for the rain gutters and got that into the shop:



A test with the wire brush showed that the privious work on removing the rain gutters was made pretty good!



Another test with the wire brush showed some additional rust, that needs to be adressed, but it is a minumum for my body work guy:

[Danish Dynamite]

Time to adress the interior. Seats and quarter windows out:



Carpets out. It looked pretty good underneath





The wonderful job of getting the old asphalt off the floors...

[Danish Dynamite]

Front and rear windows out:





Roof without interior:



Getting the two layers of old paint of the rear seat area:

[Danish Dynamite]

Debating with my self and others whether to keep these mounts or not...



I am going for a light weight car with RS carpets and no sound insulation, so here we go:















I cut gently and kept all the old brackets. I like the result...

/Christian

/Christian

[Shaun @ Tru6]

Great progress, it's a lot of work! brings back memories.

[Danish Dynamite]

More old paint removed: