Project 77 - new build

[Flojo]

geeeez that tail is HUGE !

[DHE11]

Originally Posted by Cory M

That's how all my track cars have been: low weight and relatively low power. It really is track dependent though. I was racing in a Weight/HP class and on the technical tracks the light cars had the edge, but the faster tracks with long straights and hills the newer heavier cars had a big advantage.

DHE11- you should shake it down at a POC event before shipping it across the ocean.

Next POC calendar event shows @ Laguna 4-5Aug.
While that would be very cool to drive, the logistics and timing don't work for me.
And can't really wait around till September @ Autoclub

However that will depend how it goes together over the next few weeks, then ideally take it out to Willow Springs (or somewhere else close to LA) with Tyson and give it a shakedown and set up.

Have some events at home in Aug which I'll definitely miss, then first run at our brand new track at the "The Bend" in early Sept (which I'll also probably miss)

Need to get some seat time before I go to Bathurst in December as I've never driven a LH drive car!!!
While I've driven that track a bit, and I'm sure I'll adapt to LHD quickly, Bathurst it not the best place to experiment at.... the top half of the track is concrete walls both sides and you need to be inch perfect with car positioning and judgement in a few places.

[DHE11]

Originally Posted by Cory M

That's how all my track cars have been: low weight and relatively low power. It really is track dependent though. I was racing in a Weight/HP class and on the technical tracks the light cars had the edge, but the faster tracks with long straights and hills the newer heavier cars had a big advantage.

Agree Cory,
We also run P to W classes.
The worst track in Australia to be down on power is Bathurst as there is a huge 1+ mile straight, plus another 2/3 mile straight which is up hill.
But it's also the most fun and challenging as you can make up a whole lot of time in the technical section going up, across and down Mt Panorama. Also through the kink at the end of the main straight.

https://youtu.be/GdIIjLql7Gc

This footage was from one of the last times I ran my car before selling it. Was a Porsche drive day and was 95F (36') that day, so pretty warm...
I was put in speed group 1 running with a group of 5 cars, mostly 991GT3RS's. Some track knowledge and well set up old 77 911 meant I could catch them accross the top, but was about 250HP down on the straights and climbing up Mt Panorama.
1st lap had no traffic so was giving it a go, then backed it off 10-15% on the second lap to let it cool down a little...

[Tom '74 911]

I'm not sure how I missed this thread... great stuff!!!

My '74 911 has a 3.6L engine, still has metal fenders, sunroof, some interior (but mostly stripped), fiberglass bumpers, 2 oil coolers, roll bar etc... and weighs 2,400 lbs. w/me, fuel & oil in it... or roughly 2,250 lbs. w/out driver - so I think your weight goals are realistic.

I am on the cusp of following your lead and converting my car to 100% track/race... I have been hesitating because for the $$ involved, I wonder if a Cayman GTB1 or spec Boxter would be a better bang for the buck... I know - very personal choice and hard to quantify objectively. My heart has always envisioned/dreamed of having and racing a car just like you are building. A look at the results of the groups I drive with however doesn't yield many cars like this at the top of the finishing order. I'm not sure why this is so? Maybe as the expense of running an older air cooled car has been increasing, newer Boxters and Caymans have been gaining favor...? I do still prefer the sensations of an older 911!

You have made some great component choices for your build. I'd heard that Motion Control was going to start making their own strut spindles, but until yours, had not seen any in the wild. And having Tyson help with setup is great too. Seems like he is one of the fellows who knows the recipe of the secret sauce to make these cars run and handle well. THere's nothing like driving a sweetly set up old, well balanced older 911... : ) : )

Looking forward to seeing how it all works out for your build!

Best,
Tom

[DHE11]

Hi Tom,
2400lb wet with driver is pretty light, so you have obviously been busy stripping it if its still got a sunroof and metal guards etc.

Fair to say I made a heart, not head decision to build this car (and not an entirely sensible one, as its a pretty much a ground up build, but i tend to enjoy working on my car as much as driving it). Lots of discussion up front with Tyson on the chassis and suspension design and also with MCS, who have been great with producing the custom adjustable dampers and struts.

I accept that in open racing, or even events with P2W grading, anything sub 350-400HP (I’m around 265 right now) won’t be competitive with any GT3/4, turbo 944’s or new Caymans in a straight line or on power circuits. But ill probably have just as much fun, competing with the cars in my bracket, and develop my driving to get closer to 9/10th of the cars capability.

From what i saw at CFOS earlier this year, the Boxsters and Caymans in the US are very well developed and look to have good numbers and expect if your runnning in a spec class would be pretty good fun, and competitive. However the top and midfield cars didn’t look “inexpensive” so not sure they would be much cheaper to run competively compared to an older 911...

Hard call, but am sure you will make the right one for you...

[DHE11]

Wheels with tyres fitted...

[Cory M]

Love the Bathhurst video, what a great track.

[DHE11]

Originally Posted by Cory M

Love the Bathhurst video, what a great track.

Yes, we are very lucky to have such an awesome track, and even luckier that at club level we can get to run on it.
Its only open 3-4 times a year as its actually a public road.

I received confirmation of my entry today for a November event, so assuming i can get it on a ship relatively soon the plan is to give it a run then...

[icu_jimmy]

Looking forward to seeing you and this beast there Darrien! Just got my confirmation as well. Are you doing the SS or regularity?

[DHE11]

Originally Posted by icu_jimmy

Looking forward to seeing you and this beast there Darrien! Just got my confirmation as well. Are you doing the SS or regularity?

Running the sprint on Thu/Fri...
Long way to travel, and will be one of the first events in the new car, so aim is to maximise track time and learn the car.

[icu_jimmy]

Fair enough! As for me, I can’t get the time Thu/Fri so will run on the weekend. Hopefully catch you when I arrive on the Friday. Good day at Eastern Ck today - sunny and still.

[DHE11]

Quite a few things to do this week before the engine and gearbox could go up, but is finally in...

[chrisbalich]

Originally Posted by DHE11

Quite a few things to do this week before the engine and gearbox could go up, but is finally in...

now that's got to warm the cockles of your heart.
i can't wait to hear it run. stock 3.6 or not, there's something super exciting about a first start.

[Eric at Pelican Parts]

It'll be done for November!! Can't wait to see it hit the track!

[DHE11]

Originally Posted by Eric at Pelican Parts

It'll be done for November!! Can't wait to see it hit the track!

Yes Eric,
Has progressed well over the past few weeks, and its now at the the stage of assembling lots of parts from various suppliers, so there has been a bit of “fitting” involved.

I think when you called by the shop we were talking about changing crank pulleys as PO had installed a smaller lower pulley.
Slower fan speed = higher CHT = knock sensor/timing = less power 😔

So decison was to change lower pulley, then enging frame and carrier brackets didnt fit the larger pulley, so new frame etc etc... Some Rothsport parts got ordered/delviered and problem solved 👍

[DHE11]

Ran into an issue we weren’t expecting over the past week.
As a result of fitting the 935 style suspension, the track rod locating the lower control arm has restricted the ability to get full steering lock.
Loosing a bit of lock wouldn’t usually matter that much, however our local Porsche Clubs holds hillclimbs and motorkhana’s. The motorkhanas are like autocross but held on much tighter patterns on both wet and dry skid pans, and usually require access to full steering angle.
I want to be able to run some of these events so need to modify the front suspension...


Can see in photo below track rod hits before tyre is close to the inner wheel arch.




The attachment of track rod to the lower control arm.

[DHE11]

One of the many benefits of Tyson building my car is his fabrication skills and knowledge of 911 suspension.
The build was basically a blank canvas and being an early 911 chassis with a 915 and 3.6, we looked back to Tyson’s build of Jack’s BB2 for some design inspiration. These cars will share some DNA coming for the same “creator” while using some different components, like the 935 style front suspension...

Retaining the track width/scrub radius and camber benefits of the longer lower control arms, we had come to far to compromise, so it was an easy decision to start modifying the brand new front suspension pieces!


Needed to add some material for an attachment point further inboard, and a little further forward to maintain geometry and caster / adjustability.



Cleaned up and ready to fit...

[DHE11]

Tyson’s customised lower control arms....


Before




After

[DHE11]

With the modified lower control arm fitted you can see tyre is now against inner wheel well before it touches the track rod.
This is with a 275 so dropping back to 235/245 which i usually run up front in motorkhana’s should give even more clearance.

[DHE11]

Its good to be talking about exhausts now, after months of body work.... (means finally its on the home straight)
Now engine is fitted, removing the headers that came on the engine.




Installed the set of Fabspeed headers I picked up in Australia (and carried in my bag on last trip to LA).
For testing in LA will fit the straight pipes.




When back in Australia, i have this titanium exhaust which was custom made to fit the Fabspeed headers. I was lucky with timing last year to pick this up second hand. This should be a bit quieter than the straight pipes and cover most tracks for noise limits.




Bonus was the original Fabspeed muffler came with the deal so have the option to carry and fit this at tracks with strict (low) noise limits.
All the pipes are set up with quick release flanges to match the headers so will be an easy swap if required.