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

[David Borden]

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 . 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:



To this:




Current project is this:



Thread is here: Just another 1973 911 Build

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.



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





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

More to come soon!

David

[universeman]

Awesome!

[David Borden]

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.



Programmed the CAM



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



A shot of the new shift knob in the car



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





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!

[David Borden]

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.



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



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





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

[Steve F]

Nice work David I get to play with those machines myself and a 5-Axis Haas vF-2

[Taxi!]

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

[David Borden]

Hah! Im just compensating for all my other inadequacies!

[Charles Freeborn]

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

[jjeffries]

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.

[David Borden]

Thanks Charles! PM sent...

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

David

[gsxrken]

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

[rokemester]

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

[speednme1]

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

[49willard]

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?

[David Borden]

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

David

[49willard]

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.

[tdw28210]

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).

[David Borden]

Originally Posted by 49willard

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.

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.

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).

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. If interested shoot me a PM. BTW, gorgeous interior! I love the color of that leather and the style of those seats...

David

[Charles Freeborn]

Originally Posted by David Borden

Thanks Charles! PM sent...

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

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

[Reiver]

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