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Join Date: May 2012
Location: Johannesburg South Africa
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Finally got these installed. I have a factory alu engine lid that I will eventually install, but I thought it was better to make a mistake(s) on the FBG lid...considering my track record.





Nice result.

Next step was to repair some of the previous owner's work on the petrol tank. They had installed a OE filler neck in the middle of the tank. So I removed this, installed a new breather, and closed up the hole. Then welded in a filler neck to fit under the bootlid.







Everything was going fine until I had an idea.
Now buy now I should know that when I have an idea, I should write it down and leave it for a week - until the madness passes.
Alas....





So now I have another job on my list.
I really know how to complicate life for myself.
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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 01-10-2019, 04:58 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #301 (permalink)
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This idea is to use the dimple in the existing tank in the newly fashioned shape. Hmmm. We'll see if that plan comes to fruition.
I will, regardless, add some baffles to my new 'custom' tank.

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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 01-10-2019, 05:13 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #302 (permalink)
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The CAD template.
I may well be looking for a 2nd hand tank....

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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 01-10-2019, 05:22 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #303 (permalink)
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Door cards.
Had these laser cut out of 2mm Alu.
The idea is to work a bead down the lengths to strengthen them.
BUT, the bead roller has rather sharp edges on the female die.
Which scores the edges when working the steel. So these will have to radiused....need to find an idle lathe.






Got a whole bunch of stuff back from the platers. They did a great job.
Some bits will go back along with all the MFI hardware, but overall a great result.
For comparison, here is condition of the stuff supplied to them - they did all the cleaning and prep work. For R500...which is about $40!




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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 01-10-2019, 05:38 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #304 (permalink)
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Rebuilding and servicing all the suspension parts.
Steering rack.
Stripped, sand blasted, cleaned, painted, lubed and upgraded with some turbo tie-rod ends.









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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 01-15-2019, 01:57 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #305 (permalink)
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Front suspension, with all new bushes, refurbed OE torsion bars, new ball joints and bearings. Alu calipers look great.
Boiling water, some dish wash liquid and an old sash clamp made the job a bit easier.
Working with nice clean, plated hardware makes such a change from the dirty, oily toil of the last 5 years!

Slight issue may raise its head: I have a set of oriignal hydrostatic shocks from an E that have been gutted and Bilstien'd. There may not be enough clearance between the original front anti-roll bar and the strut housing.
Anyone have experience of this?











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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 01-15-2019, 02:02 AM
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Rear suspension.
No new bearings (which may prove to be a mistake) but everything else is once again new or refreshed.





And after 5 and a bit years, the rear wheels turn!

A sandblasting cabinet is a wonderful thing. Have got carried away many times.
Decided to refurb the horn.




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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 01-15-2019, 02:06 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #307 (permalink)
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Same treatment for the wiper motor and mechanicals.
And the MFI.
Must be about 2 kg's of hardware that comes off the MFI.
All of this will be replated and reinstalled with new gaskets.
Also gives me a chance to give the motor a proper clean; removing all the ancillaries.
Must be another 2kgs of oil, grease and dirt in all the crevices.











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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 01-15-2019, 02:15 AM
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Quote:
Originally Posted by Matthew Barnes View Post

that lid needs a nice grille... from this dude: spadescustomz.shop
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Old 01-18-2019, 01:07 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #309 (permalink)
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A few updates on the build.

Finally managed to remove the remainder of the snapped suspension bolt. 1cm sheared for some reason and the Easyout was no good. What a b@#stard of a job. Rather than put the car back on the jig and turn it on its side, I decided to 'just' drill it out in situ......







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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-13-2019, 02:13 AM
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With that done I could finally get the refurbished steering assembly back into the body. And get these onto the car.



Managed to find reasonably priced, good quality tires with a period-looking side profile.





The titanium lug nuts from this forum look pretty awesome (and beautifully made btw).
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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-13-2019, 02:20 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #311 (permalink)
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Next job: reassemble the window frames.

Stripping them was a bugger of a job - those little screws that hold the frame together were very happy to stay where they were, despite a fair amount of persuasion and lots of four-letter words.

I didn't want to have them rechromed and lose all the patina (under the muck and dirt)






So cleaned up the rust, the solidified rubber seals and gave them some love with 1200 grit water paper, finishing compound and then metal polish.

I think they look awesome - fit the rest of the car.
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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-13-2019, 02:30 AM
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Back to the door cards.
A mate softened the edges of the (cheap) dies on his lathe.
Beware that the Harbour Freight-type bead Roller is a great tool for the likes of me, but the die edges are pretty rough and will need softening.

After a lot of measuring (and 4 hand-cut prototypes) I took the plunge.
Not exactly Rod Emory quality, but I'm happy with the result. Again, fits with the rest of the car. And hey, I made them myself!








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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-13-2019, 02:36 AM
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cool Panels!
great worc.

this could get the ROCS-Award (Instagram: rocsmotorsport)
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https://www.instagram.com/spadescustomz_/
https://www.instagram.com/911garage_germany/
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Old 06-13-2019, 02:42 AM
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Thumbs up

Like em!!! Vert nice!!
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1981 911SC Targa-1966 912 -1989 Alfa Spider Graduate
1967 912-1985 Toyota FJ60 Landcrusier
1985 Toyota SR5 4x4-1965 Baja Bug-1997-4Runner-4x4
1966 Bug stock-2004 Toyota Rav4-1989 XJ6 Jag
1975 914, 1965 Norton N15CS 750, 1975 Husqvarna 360 CR GP 1982 Honda 500 XLS
Old 06-13-2019, 03:49 AM
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On to the door glass, locks etc.

The pull release for the door will finish up as multistrand rope rather than bungee cord.
The lifting strap seems to work okay but the weight of the OE glass makes lifting the window a little tricky.




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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-13-2019, 04:20 AM
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Pedal box.
This has been keeping me up at night.
The original RHD pedal box was missing the clutch pedal and was generally rotten.
And to make matters worse, the bracket on the other side of the tunnel that accepts the clutch and accelerator shaft was also missing.

The accelerator is rotten as well.
The LHD box I have is missing a brake pedal.
The 964 box I have in the cupboard is rather complicated, and also LHD.

So I decided to try and save myself a 1000US and fabricate a solution.

I cut up the LHD clutch pedal and welded it back together and fabricated a pin through the welded shaft to accept a return spring.

I also drilled out the end of the clutch pedal so that it could accept a solid steel 10mm shaft for the carrier bracket.

The accelerator pedal is made out of chopped-down square tube, with the remnants of the LHD 964 accelerator bracket welded onto the back.

All in all it seems to work well, and will finish up nicely once it has all been tumbled and plated.

I'll only finish up the welds and plating once I have fitted the clutch cable, gearbox and accelerator cable - to make sure travel and tension in the return springs are sufficient.








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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-13-2019, 04:29 AM
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Then there are these buggers.
I was dreading having to import a set of period correct sport seats. They are very expensive once you factor in the 14:1 exchange rate, shipping and taxes.
So, as luck would have it, a mate of mine bought a '65 Cooper S and decided to get rid of the seats: a set of 1960s after-market Paddy Hopkirk buckets. SCORE!

I'll get hold of some suitable seat rails and weld up some brackets.

They look fantastic and are very very comfortable (for my 6'2" racing snake frame!).
I'm in two minds whether to have them redone or to just have them patched up and cleaned.







For harnesses, I was given these time-expired Willans by the same very generous mate. The hardware will be electroplated gold/yellow, the same as all the fasteners. The locks will be anodised black and the harnesses will be made up with new black webbing by a chap at the local airport who restores vintage aircraft.




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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-13-2019, 04:38 AM
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Finally, the last bit of progress.
The original visors are pretty nasty.
Being the curious chap that I am (meaning I take stuff apart without thinking about how I am going to put it back together) I decided to cut one open to see what the inner frame looks like.
Surprise, surprise.....rather beautiful.





And then my lovely wife suggested an idea....




The ply is just crap workshop ply. If the plan doesn't change I'll source some fine grain marine ply and have it laser cut to fit.
__________________
Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-13-2019, 04:45 AM
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In between jobs I have been giving the engine a refresh.
Just hardware, shroud and covers.
The shroud was knackered and cracked so that got a whole bunch of new fibreglass repairs.

Once the hardware from the MFI has been replaced and refitted, I think it'll look like a million bucks - whether it actually works or not is something we'll have to find out.





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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-13-2019, 04:54 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #320 (permalink)
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