my low budget dream car build

[AG81]

Chris,

I am laughing (on the inside) because Kelly's response and my wife's response were similar..... I work my ass off and develop a solution. I show it off to her and I get a "lovely dear" LOL. I am not sure what I was expecting but it contained more enthusiasm.

[chrisbalich]

Originally Posted by Showdown

Damn you Chris, I just bought a metal lathe. I hold you responsible.

As long as I don't get invoiced, I willingly take full responsibility for this decision.
My only regret with the purchase of my lathe is that I didn't buy a bigger one.

Originally Posted by ToySnakePMC

Nice progress for sure. Your creativity always shows up in your posts. The writing and the ideas for improvement to your toy! Patrick

Thank you, Patrick. I still get imposter syndrome a lot about this car. I generally feel more like a 30s hot-rodder than a modern-day Porsche enthusiast.

Originally Posted by fanaudical

That's a neat door latch solution!

Somebody used to offer 73 RS-replica metal pulls. I see various versions available with a Google Image Search for "73 rs door handle". That would look pretty clean/intentional or provide inspiration to make your own. I could see somebody who is used to the pull strap release accidentally pulling too hard on your non-release pull strap and getting confused...

Some tips on plastic lathe work:

- Use high positive rake tooling like you would for aluminum or use super-sharp positive rake HSS. Dull tools and neutral/negative rake create heat (the enemy of machining plastic).

- Don't bother with light skim cuts like you would use for steel; some of the plastics (like acetal) want deeper depth of cut to really cut (not just shear / smear / melt).

- A shop vac nozzle pointed near the tool helps get that continuous stringy chip away from the workpiece.

- A light mist of soapy water makes a decent cutting lube if you need it.

- Use the lathe power feed for consistent cutting along the axis; don't drag the tool back across the finished face.

- You can "spin polish" with some red Scotchbrite pads; keep it moving (don't dwell in one place).

The current pull-strap situation is temporary. I have a eloquent solution in mind, I just need a trifle more skill to execute it. I also need some more time to mull over how best to approach it.

Thanks for the tips on turning plastics. I was having good success turning the knobs. Where I had the most difficutly was having to re-chuck it because my order of operations were all out of whack. This was largely due to two things.
1. I'm still relatively new to the lathe.
2. Iterative processes tend to be...well...iterative. That's why Kelly's release button is so much nicer than mine. I was able to turn it without as much back and forth. Were I to make more, I have a clear idea of the exact order of operations required to make them beautiful.

The spin-polish is a nice idea. It would probably give it a more 'natural' finish than the machined look they have now. That might help with my conflicting textures that are going on right now with the knobs next to the RS pulls.

Originally Posted by AG81

Chris,

I am laughing (on the inside) because Kelly's response and my wife's response were similar..... I work my ass off and develop a solution. I show it off to her and I get a "lovely dear" LOL. I am not sure what I was expecting but it contained more enthusiasm.

I know, right? I've been going to bed with fingertips that feel like I'm wearing gloves trying to make this work so she will have an easier time. I finally get it pretty-well dialed, and she says, "It's easier," and she's done. What the heck? This whole thing was for you, bro.

It's not much different than when Kelly paints a whole room and asks me if I like it. I almost always respond, "It looks nice. Do you like it?" She's painting in the kitchen today, so I need to do better than that when I get home.

[chrisbalich]

Speaking of working my fingers to nubs...

Good morning, compatriots!

My parents came down yesterday to visit. And you know what that means, we went out to lunch and I over-ate.
After they left, I headed down into the garage to see if I couldn't make a decision, if not some progress.

You know that part of a project where you do a lot of sitting very still and staring at something just waiting for the solution to present itself? I've been doing that for almost two months with the GD electric heater. I know approximately where I think it'll fit, but I just can't get it right. Last night, I prioritized the defroster (electric heater) over Kelly's fresh-air duct and it all fell together...sorta.
Some 'adjustments' were required.

Here's the heater sans one of the as-supplied outlets.


I then used that removed outlet as a template.


Once more as a template


I have a selection of hole-saws, but they seemed a bit too brutish for cutting a big hole in the heater box, so I opted to take smaller bites.


And smoothed out!


Original outlet blocked off and new outlet let out



I felt so accomplished when I got to this point. LOLOLOLOLOLOLOL that was the easy part.
The ON/OFF/ON switch was mounted inside the box on the heater. So I had to cut four more rivets, figure out how it's wired, undo said wiring, extend the wiring as needed, and then re-rivet closed the box.


With the wiring extended, I could mount the heater and then the rheostat and then the ON/OFF/ON switch.

Here's all three components in situ, wires akimbo.


From there, I shortened and terminated some wires, re-engineered the power-supply wiring, and generally buttoned up the wiring.
This is how it'll look, sans the ducting.


Tonight, I need to add a fuse, connect the main power, ground the main ground, plumb the ducts, and I can fire up the car and test the system.
REMEMBER: I don't want real heat. I'm after enough moving, warm/hot air to clear the screen. I'm expecting a resounding success, but we'll see how it actually goes this evening.

I'm also a little worried I'll have to partially block the vertical outlet to force more air out the side outlet. If it comes to that, I have a plan. Shouldn't be too hard. (famous last words)

[AG81]

I am looking forward to the results. I need to work out a defrost "only" solution. Headers on and heat was removed......

[AlKidd]

Late to this handle post, but I had a passenger, whod never been in an air cooled Porsche, with me at a recent auto cross. He wasnt aware that the bright red strap in the RS door panel was the door release. He tried to use it to hang on in the corners. Worked great on right handers, not so good on the lefts. The knob is a great idea.

[fanaudical]

Funny (or not) story about the response of wives...

My wife has been car-spoiled since we've been married (she's always got to the drive the "new" car at the time - whether it was the old 100 or the A6's, now she has the Q3). She likes her heated leather seats, creature comforts, and automatic transmissions (still doesn't drive stick).

I didn't let my wife or others ride in my 911 until after ~1000 miles of break in and road test (I had the whole car apart). She rode in it initially for a for a couple local, low-speed trips. On the first "real" drive - blasting down a back road, Targa top off, sun and wind in our hair, probably a big grin on my face - I ask her "What do you think?".

She turns to me and says "Frankly, I just don't see the appeal...".

[chrisbalich]

Originally Posted by AG81

I am looking forward to the results. I need to work out a defrost "only" solution. Headers on and heat was removed......

Same. Unfortunately, I was a lazybones last night and didn't touch the car. We'll see if I can't do better tonight.

Originally Posted by AlKidd

Late to this handle post, but I had a passenger, whod never been in an air cooled Porsche, with me at a recent auto cross. He wasnt aware that the bright red strap in the RS door panel was the door release. He tried to use it to hang on in the corners. Worked great on right handers, not so good on the lefts. The knob is a great idea.

That's funny...at least for me. Your passenger likely did not think it funny at all.

Originally Posted by fanaudical

Funny (or not) story about the response of wives...

My wife has been car-spoiled since we've been married (she's always got to the drive the "new" car at the time - whether it was the old 100 or the A6's, now she has the Q3). She likes her heated leather seats, creature comforts, and automatic transmissions (still doesn't drive stick).

I didn't let my wife or others ride in my 911 until after ~1000 miles of break in and road test (I had the whole car apart). She rode in it initially for a for a couple local, low-speed trips. On the first "real" drive - blasting down a back road, Targa top off, sun and wind in our hair, probably a big grin on my face - I ask her "What do you think?".

She turns to me and says "Frankly, I just don't see the appeal...".

That would really bum me out.
Hell, that is really bumming me out and I have no dog in the fight.

[ryanjboutin]

RE:Accidental eject-o seat-o, Cuz.

I would imagine a new SOP would require the doors being locked prior to departure.
Should prevent any unwanted door behaviour, no?

[chrisbalich]

Originally Posted by ryanjboutin

RE:Accidental eject-o seat-o, Cuz.

I would imagine a new SOP would require the doors being locked prior to departure.
Should prevent any unwanted door behaviour, no?

That would be a good idea if pushing the button also unlocked the door like a modern car. As the lock and door release aren't linked in that way, I think it'd be a safety issue.

PLUS

If the door is locked, I can't decide mid-ride that I no longer want a passenger and reach across to pop the door before yanking the wheel left.

[chrisbalich]

I finished the install of the electric-heated-defroster last night. I ended up not having an electrical connector I needed to use the wiring I wanted, so I opted to use the wiring they included. The power wires are under 3' total. No wires got hot while it ran last night, so I reckon I should be good to go.

Pretty decent airflow out of the defrost vents, but it was hard to be 100% confident in the new system without an actual windscreen in the car. I got tracking info on my new windscreen yesterday, so I'm holding out hope I'll have it by week's end.

I did manage to mount/route all the (increasing amount of) flotsam and jetsam behind the mounting points for a beauty cover. So I may make something to cover this mess.

/words

[shamrok]

Got a link to that heater? I've been searching for 12v heaters for defrost-only for a while and I can't decide if it's all junk or not.

[Focker]

Originally Posted by shamrok

got a link to that heater? I've been searching for 12v heaters for defrost-only for a while and i can't decide if it's all junk or not.

+1

[ryanjboutin]

Originally Posted by chrisbalich

That would be a good idea if pushing the button also unlocked the door like a modern car. As the lock and door release aren't linked in that way, I think it'd be a safety issue.

PLUS

If the door is locked, I can't decide mid-ride that I no longer want a passenger and reach across to pop the door before yanking the wheel left.

I always lock my doors.
Always have.
Even before they automatically unlocked when opened.
Idk.

Brick > stucco.

[chrisbalich]

Originally Posted by shamrok

Got a link to that heater? I've been searching for 12v heaters for defrost-only for a while and I can't decide if it's all junk or not.

Originally Posted by Focker

+1

The heater is a DC Thermal SA12-4000.
If I had a 3.6 or a Classic Retrofit alternator, I'd have gotten the SA12-5000. I went with the 4000 as it has the lowest amp-draw I thought I could manage. (40 amps at full chat)
I expect I'm going to need a CR alternator at some point anyway, but it would have added $1000 to this project and that was simply not tenable at the time.

**I will still gladly accept one on sponsorship/donation if that's a thing.
***I reckon my propensity to clock miles in my 911 would make for an excellent torture test...even more so this year with my trip to Rennsport on the calendar.

Originally Posted by ryanjboutin

I always lock my doors.
Always have.
Even before they automatically unlocked when opened.
Idk.

Brick > stucco.

I don't lock the doors unless I can look directly into the windows of someone's soul and lock them. "I did this to you."

[chrisbalich]

Mini-update!

Last night, I tossed on the rear bumper (with license plate ) and then the front turn signals. Gabe is trying to make the trek down from MN today (through a blizzard) to help me wet sand this car. I wanted to be sure we could drive it to work tomorrow in case he makes it. Yes, that means we'll be wet sanding tomorrow at work if all goes to plan.

I also updated my to-do list for 2023.
I broke down some of the items into multiple items just because it feels good to cross them off later.
The first group is pre-Spring.
The second is pre-June.
The last is pre-September with the exception of the brakes and tach. I reckon those will likely be pushed off to Winter 2023/2024.

[shamrok]

DC Thermal SA12-4000

Cool, found this at some point then lost it, thanks.

[ADDvanced]

Get a whiteboard. I love my whiteboard.

[chrisbalich]

Originally Posted by shamrok

Cool, found this at some point then lost it, thanks.

Glad to help.

Originally Posted by ADDvanced

Get a whiteboard. I love my whiteboard.

Get a pad of paper.
You can't recycle a whiteboard.
Nor does a whiteboard tell a story. It just gets wiped clean.

[jpnovak]

Should be cold this weekend in your neck of the woods. I want to know if it heats the car.

[chrisbalich]

Originally Posted by jpnovak

Should be cold this weekend in your neck of the woods. I want to know if it heats the car.

Can confirm. It does not heat the car in 23*F with no windows installed. GD.