Projects from the shop, a window into another guy's obsession
 

Decided to create a thread that documents some of our personal Porsche related projects I've been working on in the shop. I retired from my corporate job a few months back and should have some more time to dedicate to this.

I suppose some sort of background and introduction should be in order. Ive been a member of Pelican since 2004. First Porsche was a 1973 914 2.0 appearance group I convert to a 916 tribute back in the early 80’s. Man I wish I still had that car… My wife and I purchased an 88 cab maybe 10 years ago and sold it a year before the market explosion :D. Im super lucky my wife loves these German cars as much as we all do!

About 5-6 years ago I found a super sound 74 911’s that needed to be restored. Took it from this:

http://gtmbuild.com/galleries/74_911...e/IMG_4491.jpg

To this:
http://gtmbuild.com/galleries/Niello...e/DSC_2179.jpg

http://gtmbuild.com/galleries/Niello...e/DSC_2233.jpg

Current project is this:

http://djborden.site.aplus.net/Photo...220_130156.jpg

Thread is here: http://forums.pelicanparts.com/porsche-911-technical-forum/852762-just-another-1973-911-build.html

Thinking of rolling all the build stuff into this one thread. What do you think, separate or document all my shenanigans in this one thread?

One of things I’ve enjoyed the most during my personal builds is experimenting with mechanical design and making various parts that better suite the project. About 8 years ago I sold one of my cars in progress to pick up a CNC mill, and its probably been the best purchase Ive made outside of my wife's wedding ring... Its been a blast learning to design and machine parts for the car projects I've had.

Just recently picked up a CNC lathe and have been teaching myself how to use the thing. Previously I had been using Solidworks and Sprutcam for my CAD and CAM solutions for the mill. Unfortunately, the version of Sprutcam I own does not have a post for my lathe, and Ive been hearing a great deal about the Fusion 360 CAD CAM package that is free for students, hobbyist and startups. Figured this would be a good oppty to learn it.

Needing something to make, I decided it would be fun to create a simple velocity stack. Its shape was dictated by some raw tubing I had on hand, not functionality. I've been thinking of building a set of manifolds for and ITB setup that would use motorcycle throttle bodies like the speed triples several have used, or another bike.

After a few tutorials, I was able to whip something up. It was great to see that it's fairly similar to Solidworks so relatively easy to be productive quickly.

http://lightdance.zenfolio.com/img/s...77919753-4.jpg

Then came creating the CAM and again, after watching several youtube videos I was good to go and out popped this: :D (I did take a bit of polish to it to shine it up)

http://lightdance.zenfolio.com/img/s...88839258-4.jpg

http://lightdance.zenfolio.com/img/s...78399218-4.jpg

Considering it was my 2nd part, I was super stoked with how it turned out.

More to come soon!

David

Awesome!

Thanks man, really appreciate it!

Was looking for another project to do on the lathe and decided to try my hand at some shift knobs.

I modeled up a shape that was fairly close to the factory shift knob on our early 911.

http://lightdance.zenfolio.com/img/s...89252545-3.jpg

Programmed the CAM

http://lightdance.zenfolio.com/img/s...93918647-3.jpg

Fairly impressed with the finish after 30 seconds with some scotch brite.

http://lightdance.zenfolio.com/img/s...06214904-3.jpg

A shot of the new shift knob in the car

http://lightdance.zenfolio.com/img/s...36583459-4.jpg

Ok, so now its time to experiment with wood! First we need an insert.

http://lightdance.zenfolio.com/img/s...52593760-3.jpg

http://lightdance.zenfolio.com/img/s...12019357-2.jpg

The first turned was with a really light wood, so decided to put some stain on it. Clearly I need work in wood finishing… Finish is awful, but at least it's a start!

http://lightdance.zenfolio.com/img/s...20110763-3.jpg

http://lightdance.zenfolio.com/img/s...85090859-3.jpg

A few days later, decided to try something different by using a longer insert and use the same basic profile of the aluminum knob I designed earlier but have the lower part aluminum and the upper part wood. My friend gave me some beautiful walnut to experiment with.

First the insert. Decided to try a light knurling instead of the slots.

http://lightdance.zenfolio.com/img/s...08315974-4.jpg

Then on to the old manual lathe for a quick sand and some clear urethane.

http://lightdance.zenfolio.com/img/s...03702049-3.jpg

I did a light sanding with 350 and then one coat of urethane, another quick sand, then another two coats of urethane.

http://lightdance.zenfolio.com/img/s...70035972-3.jpg

http://lightdance.zenfolio.com/img/s...42023949-3.jpg

Its different, but I kinda dig it. It feels really good in the hand… I plan to experiment with a shorter insert. Maybe half the length of the existing one and see how it looks.

What do you guys think?

David

Nice work Davidhttp://forums.pelicanparts.com/support/smileys/wat.gif I get to play with those machines myself and a 5-Axis Haas vF-2;)

David, I think .....................that I feel pretty inferior, as I don't have any of the skills you do! Can't wait to see what else you come up with.

Jeff

Hah! Im just compensating for all my other inadequacies!

Nice. PM me a mailing address and I'll send you some chunks of Walnut Burl.

I find your creations very impressive and admire the path you've chosen post-corporate life. I'm sure we could all provide a list of stuff we'd love to have you whip-off for our cars (tongue in cheek, realize there's lots of work involved). I'd like a deep hub extender to bring my steering wheel closer; first choice would be something to use with my stock three spoke wheel, second choice a deep hub for my spare Prototipo, maybe like DZug's piece. Not that you asked! Good for you. John in CT.

Thanks Charles! PM sent...

Steve... cool. 5 Axis? Man programming that much be interesting.

David

Nice to hear we might get to see some more of your handiwork over here on Pelican, David. Congrats on the "retirement".

Subscribed. Great way to stay engaged and have fun in your retirement! Good for you.

Awesome looking parts! Really like the aluminum/wood combo.

Impressive! I am afraid that I am old school, manual Bridgeport and manual 13 inch Southbend. That said I have made many parts for 100+ year old cars so the machines are much newer than the cars that I have made parts for. Did you purchase your machines used? at auction?

Thanks guys, really appreciate the thoughts and comments. John, I suppose it would be cool down the road to make and sell a few doodads for tool/fun money. Out of respect to Wayne, I would need to check with the mods to see what is acceptable re talking about it on the forum.

49, I purchased my CNC mill new from Tormach about 8 years ago? I suppose it would be considered prosumer level or higher end serious hobby level machine. The lathe is also a Tormach, but was lucky enough to find it used but in very good shape and only a year old. I like the brand because it us based on open standards controls and hardware, so repairing it would be very inexpensive compared to a commercial VMC where a repair could cost more than my mill :D

David

David,
An example of the major difference with CNC over straight mechanical machining is changing contour shapes like the wooden part of the shift knob. With non CNC you almost have to bs the shape. I assume that you could put an original piece such as a knob and "teach" to create a file, yes? Sorry for the question, I am just old school.

David (or anyone else on the thread with CnC skills),

I have a Solid Works file on my computer I received form a Rennlister in NZ. It is for a 911 arm rest (see pic below). I half-heartedly contacted a few fab shops near me to see if they could build the am rests for me. Basically they are all mostly machine shops and were a little confused by my request. Want to take a crack at running this file? I'll pay for the materials. PM me with your response(s).

http://forums.pelicanparts.com/uploa...1465469386.jpg

Yes correct. I do not have a 3D scanner, but you can use a photograph as a template to trace the original shape in the CAD software and get it very close.

Honestly that may be a fair amount of work. If you want to send me the file to look at, I can at least do that and give you an idea what it would take to machine from an amateurs perspective. :D If interested shoot me a PM. BTW, gorgeous interior! I love the color of that leather and the style of those seats...

David

Cut you some (4) shift knob blanks today. Will drop at PO tomorrow.
Lots more where that came from if you like 'em.
-C

Nice fabbing, I like the alloy knob...is that first 911 a 436 color?

Charles, thank you! Really look forward to seeing how it cuts and looks... Will post some pics once I have something to show.

Reiver, thank you as well... Color is Salmon Metallic and I think its code 036.

David

David... LOVE the fabrication!!! The machining, the turning on the lathe, the CAd... AWE-SOME!!!!!

My pleasure. That size waste usually goes into my woodstove... BTW, try the foam backed abrasive made by Norton. They're great for final sanding on a lathe - soft metals too.
https://www.amazon.com/Norton-02653-Contour-Sanding-Sponge/dp/B000KKPE74/ref=sr_1_fkmr1_3?ie=UTF8&qid=1465919630&sr=8-3-fkmr1&keywords=norton+3x+foam+sanding+pads

On wood go all the way to 320 grit, then seal and finish. For figured wood (like the Walnut) I use Seal Coat by Zinser:
1 Quart Zinsser Bullseye SealCoat - Rockler Woodworking Tools
Then Gel Poly:
General Finishes Gel Topcoat - Rockler Woodworking Tools

You can skip the sealer step, but it will take a few to several more coats of topcoat to get a build.

BTW, beautiful part of the state you're in. I lived in Oakland for 25 yrs before moving up here. Used to take drives all through the foothills for many years.

David,
Nice work.

regards,
al

Thanks you, appreciate the comments!

Charles, I got the wood, THANK YOU! Very nice looking pieces... Hoping I will be able to take a stab at it within a week. Thank you for the suggestions on finishing. Do you know if they make that same stuff with UV protection? Some of my friends cars are open including a couple of mine.

Spent a fair amount of time making soft jaws for the 3 jaw chuck to make the chuck run more concentric. Should have them done tomorrow.

David

A ton of time has been spent in the shop the last week or so with some great progress on the shift knob project. I've become a bit obsessed with it. :D

What has been a great deal of fun, is many of my friends have been providing input on design and giving me wood to try, including Charles! It's been a bit of a community project.

First line of business was to create some soft jaws on the mill. As mentioned before, I was working on soft jaws for my 3 jaw chuck. This type of chuck is not very concentric, but if you make soft jaws, you can true them up once installed.

http://lightdance.zenfolio.com/img/s...82547013-3.jpg

They almost got the best of me… These things took the better part of a couple days to design and machine to the point where I was happy with them.

http://lightdance.zenfolio.com/img/s...87729537-3.jpg

In the end it was worth the effort as I was able to reduce the chuck runout from about .004” to .0005 - .001” which should be good enough.

http://lightdance.zenfolio.com/img/s...07898052-4.jpg

Another beast lurks in the garage… This car took about 4 years and a couple thousand hours to build. What's another 10 for a shift knob?

http://lightdance.zenfolio.com/img/s...87794768-3.jpg

My friend Brad has been providing some good feedback. He is a mechanical engineer so told him to design up a dream knob for his 68 Camaro project and since the cobra was in the shop, it gave me a guinee pig for the project :D

Making it an assembly so that each part is referenced to another, you can make them nearly a perfect match so they feel smooth in the hand.

http://lightdance.zenfolio.com/img/s...80522046-3.jpg

Each piece separately.

http://lightdance.zenfolio.com/img/s...94438357-2.jpg

http://lightdance.zenfolio.com/img/s...15407152-2.jpg

Insert off the machine.

http://lightdance.zenfolio.com/img/s...07733200-4.jpg

Some Walnut my friend Tracy gave me chucked up and ready to try.

http://lightdance.zenfolio.com/img/s...08482574-4.jpg

The wood just slipped onto the insert before finishing

http://lightdance.zenfolio.com/img/s...16032490-4.jpg

How about a quick finish on it..

http://lightdance.zenfolio.com/img/s...27790365-4.jpg

Overall it turned out great.

My friend Tracy who is an avid wood worker started making some sample knobs at home to get ideas for combining different woods and finishes… Will post some pics in the next few days.

Charles, I made my first knob with the burl and will post some picture of it soon! The wood is gorgeous in the sun…

As always, let me know your thoughts...

Charles… so thanks again for the wood! Finally got to the point of feeling confident enough I wouldn't screw those beautiful pieces of wood up and took a shot at it.

http://lightdance.zenfolio.com/img/s...80297151-4.jpg

Chucked up the worst piece and did an initial turn on it. It really cut well! Took about 10 minutes to sand it and then put a couple coats of urethane and this is how it turned out… I cant believe how it pops in the sun.

http://lightdance.zenfolio.com/img/s...25573220-4.jpg

http://lightdance.zenfolio.com/img/s...56433202-4.jpg

Im working on a modified version for the 911 now.

David

Many hours have been spent in the shop over the last few weeks playing with the shift knob project. One of the issues is figuring out how to hold the insert for the air cooled Porsche after its machined.

Came up with something for a split arbor that would be a slip fit but made in 2 tapered pieces.

http://lightdance.zenfolio.com/img/s...57887956-3.jpg

By making a little slip fit collar, I am able to use the same arbor for holding .750" ID parts.

http://lightdance.zenfolio.com/img/s...59881706-3.jpg

Hey Charles.... check this out!

Using the wood you sent me, I re-shaped the 911 gear shift knob and shortened the insert as well. It now measures 1.77" at its widest part and feels wonderful in the hand.

Its hard to believe that this:
http://lightdance.zenfolio.com/img/s...80297151-3.jpg

Now looks like this:
http://lightdance.zenfolio.com/img/s...23538803-3.jpg

http://lightdance.zenfolio.com/img/s...38370637-3.jpg

A good friend asked if I could make him a shift knob for his car out of African Black wood. He purchased a blank of wood and gave it to me to experiment. This is the same shape of the Burl wood above.

Its really incredible looking. At first look, it looks truly black... until direct light or sun hits it and it has a dark grain that just glows. These parts have no stain on them, just an exterior clear urethane.
http://lightdance.zenfolio.com/img/s...35149442-3.jpg

http://lightdance.zenfolio.com/img/s...81940175-3.jpg

Here is a shot of these two along with another cool one I made out of a laminated piece a good friend made for me. He's a really talended wood worker.

http://lightdance.zenfolio.com/img/s...04759445-3.jpg

David

Sweet

Outstanding!

Thanks guys!

Charles, how do you want yours? As promised, I am going to make you one for sending me the wood.

I can use a piece of what you sent me as I have one left, or if you want to send me anything else just for it thats cool as well. I can get it to you finished or I can send you the two parts and you can do whatever you do as well. Im still a complete noob at finishing wood.

What do you guys think of the insert? Should I make any changes to it? What about the shape of the knob?

This is fantastic, love it. Can't wait to see what you'll come up with next.

andy

David,
Excellent functional art.

regards,
al

David, I think this is really cool. Based on the pictures, you are very passionate about being a perfectionist. It definitely shows in your work.

My old '74 was Salmon Metallic...... love it!!

https://c1.staticflickr.com/9/8734/2...46f88194_o.jpg

Love that '74. Right on.

Thanks for the comments, they are definitely appreciated.

George, nice looking 74... Its interesting how the color can look so different depending on the light.

A friend of mine just handed me a big chunk of Ebony to turn. Will post some pics once I have something worth showing. I don't think I've ever seen the wood before, so its going to be fun to play with.

David

I'll cut some more material for you then you can choose which for me. Makers choice! I have some really cool Eucalyptus that came from a vineyard in Napa. Wild figure. What are the rough dimensions of a blank?

Congrats on PCA E-brake photo of the month for June! Great pic!

http://forums.pelicanparts.com/uploa...1470140024.jpg