Torsional Rigidity Measurement...warning pseudoscience involved

[JohnJL]

Mocked up an intake manifold. I am using a 3.5" 90 degree cf elbow, and constructing an airbox to hold the filter and manage airflow. The box is made of 2mm cf plate from dragonplate.com. The corners are reinforced with 2cm 90 deg channel bonded to the box sides.

I have a "trumpet" I will contour and bond into the airbox before sealing it up.

I am using Hysol e120 epoxy. It is thin and runs even in low temps with a 2 hour wrklife so you have to be careful to use only as much as you need or it will flow out.


I found using rare earth magnets on either side of the seam being bonded works really well at holding everythng in place where clamps couldnt reach.

[JohnJL]

More bonding between periods...

[JohnJL]

Airbox progress, and the clutch pedal cable, throttle linkages and pedal cluster in place. the throttle linkage took some modifying. I had to add 3cm length to the upper linkage arm.

[JohnJL]

Airbox done...it just clears the tail grill. I was hoping to set it deeper into the engine bay and made a shroud for it but where it sits will need some more work to have the shroud/filter holder clear the tail. IAT sensor fitted and idle valve intake also fitted. I used some carbonfiber/kevlar rod to make the rear box support.

I am pretty happy with it, but will have to see how it works in the rain/being washed.

[JohnJL]

Some work on the windows, door latches and door cards. In another thread some asked:

'[QUOTE=911tracker85;9488790]so how did you do this conversion? as I strip to the tub, already pulled everything out of the doors.

I am planning the same thing for my 930 conversion project. plan to use RS door panels. also removing PWR mirrors.

saw this done on a 944.

"

Originally Posted by 911tracker85

so how did you do this conversion? as I strip to the tub, already pulled everything out of the doors.

Here are 2 ways Ive done it...the first and darker pics are from a 1982 race car. it has no door cards and the window itself is Makrolon. You pull it up with the yellow rockclimbing sling.

The later pics with the white door interiors are from an autocross/street car. Again, stripped out inside but this one has carbon fiber door cards from GT (also pictured.)

The problem with the way that 944 has them is the strap can fall down inside the door. I've found it better to create a full loop for the handle with grommets as you see on the 944 and a "peg" to hook the window sling into to keep it up/partway up. The loop passes up and out the top of the window, inside the car, and inside the door through the door card at the bottom. That way it never falls in.

The second car is in progress now, the black sling is the window pull that doesnt have its grommets yet. The yellow rope is the door latch, and it will get a third sling to pull the door closed at the end. The triangular cutout you see in the door card is to accommodate a gusset in the corner of the door. I've bonded in a spacer, then will back it with another piece of carbonfiber.

[JohnJL]

Backtrack to the other post:

Spray dry graphite is your window channel's friend

[JohnJL]

Its coming together...door cards in with window and lock pulls. Pedals installed and adjusted. Driver's side seat, swithes and steering wheel. I even sat in it and shifted and turned the wheel making squeeling tire and motor noises.

Been waiting 3 weeks now for the MS cable from EFI analytics...it should theoretically start. All fluids in and no leaks other than a drip from the s hose.

[JohnJL]

Dash and dashboard from sept 2015

Cleaned out all the old crap foam and bits. Taped up a "dam" around the preimeter and filled it in with dense Hilti foam. The covered with fiberglass, then foam and then Alcantara.

[JohnJL]

Its official...898.5 kgs...1981 lbs. Wet, with me in it.

Not bad for an initial weighing. Now to work on the corner balancing...

[JohnJL]

Well that was a record corner-balance session! 7 turns out on the left front and 15 turns out on the left rear and it was all within 1.2 kgs on each corner from perfect. 50.5% cross weight. The fronts are within 1 kg. It will settle a bit after driving it around, so I will leave it there and come back after a test drive.

I had planned to have the F1 on in the background while I tinkered with it but I am done before the parade lap is over!

[JohnJL]

Car starts and runs. I need to do some more work on the idle and fuel/spark maps but its close to ready for the road.

I love the seats, they really fit me and hug you in. The stock belts work OK, thought I have harnesses waiting to put in. The shifter needs some bending to get it just a bit higher and give some more room for the hydraulic parking brake.

[JohnJL]

more

[Flojo]

uff, missed this build completey. great job. and a back-date one of a kind!

some fresh pictures (art-shots)?

[Nux]

Originally Posted by JohnJL

Its official...898.5 kgs...1981 lbs. Wet, with me in it.

Not bad for an initial weighing. Now to work on the corner balancing...

Lightweight baby!! Job well done!!!

[JohnJL]

Well Gretchen is basically done! I have a much better idle and have done a few tuning runs. Starts right up and catches itself when off throttle and into idle. Brakes all bedded it, and the alignment adjusted so it runs and brakes straight and balanced. Unfortunately its into storage now for the winter, but she will be all ready to go after last snow in the spring!

[JohnJL]

Six months later and Gretchen is on the road! Insured, plated and ready for safety inspection at the garage up the road. I did some transmission tunnel mods and will post that later, in the meantime I've had some requsts for VE and spark tables and files...here they are. It hunts at idle and stalls off throttle so there's that. Happy for suggestions here. It has ~5 miles of VEAL tuning on it and generally starts and runs well with sharp acceleration. I had this motor dynoed in another car with a CIS intake with adaptronic EFI giving 240 at the wheels. With the carrera intake, MS2, DC24 cams and MK exhaust it feels like 270. In 899kgs she is a ripper! (thats 1,981 lbs)

[KNIGHTRACE]

Wow, I have to say this guy did some of the coolest stuff I have seen in a long time. William Knight

[JohnJL]

Its been a while...all tuned up with M&K headers and muffler. Sounds glorious.

[KNIGHTRACE]

very nice build