Project Olly

[Industrialando]

Originally Posted by Flojo

Uh, didn't expect that?!

carbon lightweight panel?

the front lip of the upper window frame looks gone(?).
how you gonna mate that new sheet?

I was wondering the same thing, but Stratton Motorsports knows what they are doing. I’ll post up pics after he welds in the roof skin.

[75 911s]

Just looking at the pictures and knowing how I'm going to do my roof skin I would surmise that they are taking the front off at the spot welds that lay just below the window seal.
The new skin will spot weld onto the front and then weld along the cut line along the sides of the car. The front lower lip is still there, but the old sunroof skin still needs to be drilled out and fully removed from the front lip spot welds. Just an hypothesis, as the picture isn't all that clear.

[Flojo]

one more thing: try to secure/save your steering wheel from being damaged.
it is an original 3-spoke sport wheel and looks to be in good condition.
these are worth a couple of 100 USD nowadays.
you don't want to ruin that during your build.

edit: get a cheap Momo Cavalino C36 from eBay as temp replacement

[Industrialando]

Long overdue update,

Backdate work is progressing and we are now primed and almost ready for color, we’re using Glasurit and I’m sticking with Irish Green. Sunroof delete and complete roof reskin turned out fantastic, the donor roof was in great shape and local so we got lucky. Decided no ducktail which I think will be a good look, the look will be aggressive enough given the flares so no need to go crazy. It's really coming along and starting to look like the car I envisioned, hopefully we'll have finish paint on in a couple weeks.






While the car sits at the body shop I've been working at home to restore the window frames. After searching through this site I found enough info to give the courage to try restoring them myself. I'll say it's become much more difficult than I expected, but in the end they will look awesome. I've decided to go with the brushed aluminum look rather than a mirrored polish. Here is the difference:



I plan on going with Braid fuchs (9" front, 11"rear) which will have a brushed aluminum finish, rather than mixing up metal finishes I think going with brushed window trim, decklid grill and horn grill will tie it all together.

Lot's of trial and error on the aluminum frames but the process that I've found to work the best is:

- Strip Anodized layer with Easy Off heavy duty oven cleaner, do not use anything else as it will not even come close to doing the job.
- 5" orbital palm sander: Start with 100 you will see the anodized layer peel away, surface will feel slightly rough so I use 180 as the last step with the palm sander. Try not to build up too much heat as these parts will warp.
- From here it's all elbow grease: I used 3M dry/wet automotive sandpaper and it worked the best. I used water which seemed to help. Start with 220 and work your way up to 2000.
- Now to the polishing wheel, I used Mothers metal polish and out of all the brands it seemed to be the best performer. If you are going for a mirror finish you will want to do a rough polish, then use 0000 steel wool and then back for a final polish. If your going for the brushed aluminum look just stop after the steel wool.

Once your done off to a local shop for a clear anodize. I'll say that if you're a perfectionist or have severe OCD go ahead and send it to King of Trim or another trim restoration shop. Throughout the process you will see so many imperfections and nearly loose your mind, but if you can live through the visual shock it's actually not that hard to do. My frames were beat with scratches, yet in the the end they will be nearly perfect so it can be done.

[Industrialando]

Out of the bodyshop and back to the garage, extremely happy with the results Stratton Motorsports did a awesome job from the backdate, bodywork, roof skin install and paint.

I'm now on to interior prep and sound deadening install. After looking at the wiring and complete mess the PO made with various stereo equipment it appears I'll need to reach out to Kroon for a new harness and dig into that next.

[Flojo]

damn that pops !!

[Industrialando]

Currently working through interior cleanup, original sound deadening demo, prep and hopefully new sound deadening install soon. In the meantime I knocked out a quick pedal cluster rebuild project. This thing was in bad shape, cant believe it was still operational.

BEFORE:



AFTER:

[ToySnakePMC]

Thanks for sharing updates. This is going to be a beautiful project! Love the Irish Green.

[Industrialando]

Interior project continues with factory sound deadening removal, straightening a few floorboard dents, painting with rust inhibiter and finally Dynamat Extreme sound deadening to finish it off. About 35 hours total but really only worked 2-3 hours at a time given the super awkward position this project puts you in, brutal on the back.

Next up, gauge restoration and slight modification currently being done by jbell959. Under dash and dome light wiring. Dash prep and paint then mock up final dash facia configuration (adding AC vents) then install headliner. Long way to go but making progress.

[Industrialando]

Also, received my custom 915 shifter from 911SPete, beautiful work and cant wait to get this installed. Anyone looking for a unique look and about 3/4 the price of Wevo check the parts forum I believe he is still selling these.

[Industrialando]

Next up on the list: undercarriage and removing the factory rubberized coating, prime/prep and re-coat. After much trial and error I found the best approach for this project is an oscillating tool with a flat blade (not serrated).

Once the bulk is removed I used a wire wheel to strip the residue and bring it down to bare metal. Tedious project no doubt but after about 5 hours I’ve managed to knock out a little over half the pan. Here is the progress to date:



While this project was underway I had the gauges sent off to Jbell959 for new glass/painted bezels as well as custom work on the tach. John did an incredible job, added a clock and custom painted the face with the some leftover Irish Green paint (Gasurit) that we used on the body. It looks incredible, I highly recommend John for any custom gauge work.

[Pedro '84 Coupe]

That tach is cool! Roof and paint turned out great too. Wish I had those skills.

Maybe I missed it but what's going in place of the clock in the dash?

[Industrialando]

I’m undecided on what to put in place of the clock hole. John is working on an AFR gage which I’d prefer but he’s still in the R&D phase. I thought about adding duct and making it an HVAC vent but the only vent I’ve found is the F150 design, not the greatest of looks. I wont be ready to reinstall gauges for another 2 months so hopefully the AFR will be ready by then.

[Industrialando]

This project is moving along slowly but made some decent progress lately. Major milestone reached with an engine drop, CIS runners removed and prepping for a tear down. After much thought I’ve come up with the following build specs as this will be an EFI conversion, feel free to chime in with any thoughts/recommendations:

Motor Specs
- Pistons: JE - 95MM - 10.5/1 Comp
- Cam: DC60 (Possibly 964 as a more streetable cam)
- Rods: Porsche OEM/Possibly Pauter
- Heads: Twin Plug
- ECU: AEM Infinity 506
- AFR Sensor: AEM
- ITB's: Rasant – Anodized
- Injectors: Bosch
- Fuel Regulator: AEM
- Cam/Crank Housing: Rasant
- COP: Bosch (Maybe Weapon X)
- Springs/Retainers: Aasco
- Head Bolts: Supertec
- Rod Bolts: ARP

Machine Work (Likely going with Ollies)
- Crank - Cross Drill/Groove
- Crank Balance
- Rod Balance and Bushings
- Flywheel Reface
- 3 Angle Valve Job
- Head Polish
- Twin Plug Heads
- Clean Case Oil Squirters
- Check line bore and machine as needed

Cosmetics:
- Fan/Housing: Cerakote Silver by Sean @ Tru6
- Fan Shroud: Amber
- Cam Housing: Cerakote Silver




Continuing on, I received the oil tank back from Pacific Oil Cooler Service and they did a fantastic job. Extremely happy with their service and turnaround time.




Finally, with the most recent 10% off Braid wheels offered by Pelican I pulled the trigger on a set of 9x11’s. Quick test fit and these bad boys look great. Will be a while before I’m ready for them but figured these were a great deal. Will be looking for TB15’s this summer for hopefully a winter completion and drive.

[CarlP]

Beautiful Car! More or a RSR/IROC guy myself, but this is going to be awesome!

[jpnovak]

Great build.

But I can't help but think how spectacular it would have been in that original blue color shown on the interior...

[Industrialando]

Originally Posted by jpnovak

Great build.

But I can't help but think how spectacular it would have been in that original blue color shown on the interior...

Mexico Blue, I lost count of how many hours I thought about going with the factory color, but in the end the build is totally custom so I decided to go with my favorite color Irish Green and will use tan interior.

[Industrialando]

Care package from dg567 (tiporscheproducts.com) received today, excellent quality and can't wait to get these installed.








Seats are also progressing with just some tightening/misc. finishing left to do so this isnt the final look, going with a tan interior (Veteran Leather Co.) and really fired up about this color with Irish Green exterior. Back seats, side panels and door panels are all getting the same leather treatment. Planning on going with an oatmeal squareweave carpet to finish it off. It's coming along......slowly.

[Industrialando]

Quick update on progress, it’s slowly taking shape and all the small projects are coming together. I’m hoping to have the car on the ground and finally out for a cut and polish before final assembly of finishing parts.

The engine is taking shape by the fine folks at JB racing, this is a mockup to fine tune muffler location, and we’ve decided to go with Rarely8 headers which look incredible. Can’t wait to hear this thing, basic build details are: 3.0 -> 3.5L, twin plug heads/ported, JB racing aluminum cylinders (steel sleeve), PMO carbs, crank modified by JB (mains cross drilled, etc.). A lot more details here which I’ll share once JB is wrapped up and we have dyno results.

[Industrialando]

The entire brake line system has been replaced and PMO restored calipers installed, based on recommendations from PMO we decided to go with aluminum S calipers on the front and a 23 MM master cylinder. Overall easy install and well worth the piece of mind.