914/6 GT Engine Lid Conversion

[David McLaughlin]

914/6 GT engine lid conversion:

First, let me say that when I started this project I thought that the factory style lid looked unfinished and a little rough. I had seen pictures on the internet of a car that had the same style grill material as the stock openings and side grills. Sorry, I don’t remember who’s car this is or even where I lifted the picture.
PICTURE 1

This is not how the factory made their lids. What they did was probably much easier and faster. Also the grill material they used looks a bit lighter. I believe they uses a stretched mesh of some sort.

[David McLaughlin]

To start the project I bought a used lid off ebay. Unfortunately, it was quite a bit rougher than the description said and to make matters worse, I paid the guy twice due to my lack on online payment experience. Live and learn. I would recommend starting with a lid in good condition to eliminate prep work later. I also bought another grill off of a Pelican Parts BBS member. I was much happier with that transaction. I would recommend asking the BBS member or rennlist member for parts before looking on ebay.

I disassembled the lid and kept all of the pieces for use later. I will be ordering the speed nut from Pelican when I am ready for reassembly. Using masking tape, I marked a rectangle in the solid top about 1” in from the edge. I used this line to guide my cutting wheel. (Note to self: Don’t cut so deep as to cut into the supports when doing another lid)
PICTURE 2

[David McLaughlin]

The actual metal removed is only about 4” across. As you can see, I made an additional cut about 1/2 inch and 45 degree at each corner.
PICTURE 3

At this point, I also removed the diagonal brace for a lighter lid and that much more air flow. I have seen some companies just use a hole saw to cut a bunch of 2”(ish) holes. It all depends on how much work you want to do. I figured that grinding spot welds was easier than spacing holes.

Now that the opening is mostly done, I used a pair of sheet metal working vice grips (these have a large flat clamping surface of about 4”) to bend down the edges for a more finished look. If you are not overly particular, I would eliminate this step. I was originally going to put the lid within this opening, but decided otherwise later on. Ok, truth is I couldn’t get the multi curve angle to work.

[David McLaughlin]

This is one area I had a bit of trouble. Being as particular as I am, I could not get a sharp enough edge on my bends. More work is still needed, but at this point, they don’t look too bad in person. You will find that a few more cuts are needed to make the folds over the front to back structure.
PICTURE 4

Now all four sides will bent under at 90 degrees.
PICTURE 5

PICTURE 6

shows a much better opening and I still have one side to bend.

[David McLaughlin]

Now, I go to the spare grill and flatten all but the sides. There is a subtle curve in the stock lid that you need to get rid of.
PICTURE 7

I’ll use the sides to pop rivet the grill onto the lid. Again, using tape, I bend down the grill to match my newly cut opening.
PICTURE 8

I needed to notch the grill a little to fit over the part of the lid that makes up the new frame.
PICTURE 9

This is where a lot of trial fitting is needed and I lost patience. I suppose it all depends on how picky you are.
PICTURE 10

[David McLaughlin]

Once I’m happy with the fit, I’ll clean up any rust and spray all pieces with a nice satin black. Then I’ll get out my handy rivet gun and pop it all together. I hope to finish this thing and get some completed pictures.
Here is where I stopped. I probably only have another hour or so on fitting and getting the edges the way I want. Then paint and reassemble.
PICTURE 11


It’s not all that hard, I just found other projects that needed to be done first. Good luck to anyone attempting this and please feel free to contact me if you feel I left out a step.

djm914-6@attbi.com

[Zeke]

It's hard to describe a fabrcation process. Anyone who has tried to follow instructions provided with many assembly-by-purchaser products knows this. David, you did a splendid job. The only thing I did different was that I flattened out three sides and hooked the rearward bend down in front of the orginal grille to avoid any rivets at the center joining of the grilles. I couldn't describe that very well in my other post in the other thread; can't really find the right words now.

If we keep going like this, there will be more GT grilles than there were GT's. Maybe we should start a club like the SC World Domination over on the 911 board. What would we call it?

[watsonrx13]

David, great job on the fabrication description. When I'm ready to redo the engine lid, this is the post I'll use. Thanks

[David McLaughlin]

Zeke,
I won't have any rivets showing either except on the sides. I will rivet the front and back ot the top grill to the flaps that I bent down on the lid.

The last picture shown was only ment to give an idea of the final product. At this point (sorry no pics) the grill fits within the cut out on two sides, the other two hang over the lid like the original grill. I had meant for the other sides to fit within the cut out too, but gave up in the curve.

Thanks for the compliments.

[ajserrano]

Reviving a very, very old thread---the link below shows how we're doing it.

914-6 GT Engine Bay Lid - 5 More Pieces Now in Production (July/2016) Photo Gallery by 914-6 GT at pbase.com





...the hard way.

[Matt Monson]

Hey Armando. I hope all is well.

[Dave at Pelican Parts]

I love seeing posts from Armando with pics! The fabrication work he shows off is always awesome.

--DD

[ajserrano]

Hi Matt! All is well, and you?

Thank you for the compliments Dave---helping a couple of friends with their own 914-6 GT projects. :-)

[PCA7GGR]

Nice work.

[ajserrano]

Originally Posted by Dave at Pelican Parts

I love seeing posts from Armando with pics! The fabrication work he shows off is always awesome.

--DD

Hi DD, here is the latest, completely 're-tooled' for a proper 914-6 GT engine bay lid conversion. See here

Below is a "Kodak Wow Moment"...



Two more photos below, the rest can be found here.

This is as close as we'll ever get to "free-handing" a shape, holding a hammer and 'form-chisel'.



And the results from all the hard work. Of course, not yet finished.



PS: When compared to my previous post and photos, Holy Moly! I can't believe we did that! LOL

[ajserrano]

Glorious.... Done!







Oops! Wrong photo...

[ajserrano]

Two more...





Damm, these other photos keep getting in the way!

[ajserrano]

Glorious!!!

[ajserrano]

A short video clip showing the new tooling in action...