Shouldn't you plan for convenient service/replacement as well? Polycarbonate will scratch and visibility will change over time. No problem?

Sherwood

Yes, i am going to use a silicon or rtv to glue the window to the frame. When i need to replace the window i can "saw" through the sealant with a wire and replace the window.

Good. At first, I thought the structural adhesive was for the window.

Got some motivation in the mail today...sorry a couple are sideways, I dont know why Pelican render them that way.

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They are going to mbe mounted in these...CF fenders. They take some fitting but I am enthused...now back to the roof....


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I got a bunch of stuff done, with a couple of track days sprinkled into so Im a happy guy.

I glassed in mounts for the headlights, then trimmed back the fender. Taped it over from the topside and glassed in the backside. The plan is to then trim back to the light lip so the trim piece snaps right into place.

I spent a LOT of time aiming the headlights and positioning them when putting the mounts in place.

Also got the front bumper fitted and mounts fabricated and glassed in.

Maybe tomorrow I can cut the rear reflector panel out and fit the rear bumper.

The headlights have really been a challenge. I am learning for sure. Here is a camera dump.


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So Ive never done anything like this before,, but so far I am pretty chuffed with the result. Overnight the glass all cured right and the tape comes away cleanly. I need to get a knife in around the edges to release the heaqdlight unit. Once that's done I will go back and clean up/finish the glass work with the headlight out of the way..




http://forums.pelicanparts.com/uploa...1436708177.jpg

It will take some work to blend it in and look good but I am pretty happy with it so far.

Spambot reported.

More filling and mounting of the passenger headlight. I hooked up the headlight to a battery and checked the light pattern. I got it centered and in the center of the headlight's adjustment range in both directions. I also checked the adjustment screws moved the pattern enough so I wouldn't have problems later.

The side shot with the nearside passenger fender cut and the farside driver's fender in the original 911 profile shows how much difference there is, though to my eye the car still very much has a classic 911 'face.'

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Got the second light positioned and the mounts glassed in. I hope to finish the first layer on the backside of it tonight.

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Also got the rear bumper fixed in place. I cut out my rear reflector panels and fit the bumper against the flange I formed. Then I tucktaped the edge, and added release agent and put a first layer of glass in to form a lip on the bumper that will bolt onto the body flange.



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I have to compliment GT Racing on these fenders, bumpers and hood. Everything is fitting right on with very little massaging. Very light with good finish. He did mine about 2 years ago, if I recall it was 2 layers carbonfiber, 1 layer Kevlar?

So this is my build thread now I guess...

Spent 4 hours blasting the tub today. Another 6 hours stripping paint and filler from the doors, forming the metal edge around the doors, filling in the mirror holes and got onto the dash. I want a very simple dash and it doesnt get simpler than this. Almost all the vents are bloched off, heater controls, switchgear, lights, radio, everything is blocked off and glassed behind or filled in. I got 3 layers of glass and 3 layers off metal filler on tonight.

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I glassed in the bumpers and mounts, welded on brackets on the car and blasted them for primer.



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I have a set of plastic lightweight front and rear turn signal light boxes from SMC.

The lower dash and up around the instruments will be one continuous surface in paint. The upper dash will require some work, involving foam and fiberglass finally finished in alcantara.

So my bumpers are mounted without the use of the OEM bumper mounts or the towhook. Any reason the areas in red cant be cut off? They look like about 5 lbs of dead weight right at the worst space.

I did a bunch of bracing to the rails/across the corners in the engine bay. Those mounts dont look like they add any bracing and are now superfluous?

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No rear reflector panel needed.

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Front fender and bumper mounts. Front roll bar mount reniforcements welded in and blasted back for primer. THe backsides of the seam welds dressed for primer.

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Patch panels all stitched in, including torsion bar covers.

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Back on the rotisserie and front ready for washing/degreasing/primer.

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Strut towers braced in, cleaned up and almost ready for primer. I need to patch in and shape the camber/caster holes a bit and make them pretty.

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Pedal area. There is a thick plate welded in hte outside in front of the cluster mount to encourage a firm pedal.

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Front oil cooler ducting cleaned up and ready for primer, seamsealer.

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Another day of media blasting, degreasing and primering the raw metal. Wife wanted the garage powerwashed out too so that was another 3 hours...





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What kind of mig welder do you have? pic?

Lincoln 180c with 75/25 gas. Its in the background in the 4th pic from the bottom.

Continued welding in new lips for the 993 flush-mount rear quarter window seals. I was able to play with the size of the opening so that I think it will end up flush with the body all around without altering the seal at all. Lets see. The window will be from a piece of makrolan I have.

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Another 10 hours on fabricating and welding in new quarter window lips, oscillating scraper and cup brush on the bottom



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Just noticed tonight Evercoat Metal 2 Metal features a 911 on the label...

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Its been a while, a good bit of progress to report. Underside is finished, Frunk and engine compartment are painted and done. Tonight I did a few coats of filler on the lower dash. I foamed in the upper dash, shaped and sanded it back then put a layer of fiberglass on. When that sets I will put some foam on and finish with alcantara...

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more

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Replacing the dual wipers with a single wiper
 

Here's another rabbit-hole project I am building into her.. I have seen a few threads on lightening the existing wiper and linkages, and mention of the use of a 944 rear motor (NLA) and I have seen those 79-80 Sciroccos with single wipers.

The route I am trying has the goals of 1. passing inspection, 2. keeping my wind shield clean in light rain for limited time (ie not expected to deal with huge downpours, ice or now) and 3. lightweight and 4. accomodate a single wiper in fitting in the the streamlining I have done on the rest of the car.

I settled on using a rear wiper motor from a Jeep, across their range from the 90's through the 00's. Interestingly it arrived and is a Valeo unit. So before anyone gets all insulted for putting Jeep parts on a Porsche, its the same manufacturer that makes many of our alternators and regulators.

THe unit is very small and lightweight. WHen I get a chance I will dig up the original motor and linkage and compare the weights.

The dimple the wiper arm sticks through the body fits the Valeo unit perfectly. Of course I have 2 of the dimples to accommodate the original wipers so having confirmed there is plenty of room under the dash for a bracket and the motor, I plan on cutting out both dimples and relocating one of them to the center of the car. Then patching in the two old arm hole.




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