R / Outlaw project...

[jury]

Said it before, but there is always someone who can take a better photo than you can.
Photos by Ty Milford, Photographer and partner of Rennfilms:

http://rennfilms.com

A snap shot from a Saturday morning...













Cheers
Chris

[jury]

Front skid pan fitted...finally.

Good fit, and might also help with front to back weight distribution

[fanaudical]

Hey, Chris - It's great to see you posting here again! Your car is still one of my favorites and it still looks great!

[jury]

Looking back to 2017... All was going great until I could no long find second gear! At first I put it down to the shift coupler, but after re-bushing and adjusting it still persisted. The engine and Gearbox were dropped out of the car and a new clutch and throw out bearing ordered. Strangely the throw out bearing that was fitted was "twisted", no better way to describe it. The clutch would engage but the bearing was at a noticeable angle. Anyway new stuff fitted and the problem fixed...or so I thought. The car still would still not shift into second, it would just about slot in at idle but no chance whilst moving. So we decided to nurse the car to the Emory Campout (the first few sentences of this thread state that I wanted to build something inspired by the Emory specials, so I wasn't going to miss the opportunity to show the car in person to those guys) with some interesting footwork and then investigate further on return.

Enroute to the Emory Campout



The gearbox was removed again and then delivered to German Transaxle in Bend Oregon. The guys at German Transaxle were great and took me through the tear down process...

[jury]

It quickly became obvious that the Gearbox would need a full rebuild. The synchros were shot as were the slider gears, the gear ratios didn't look too bad but there was wear to the Pinion gears and diff. I was happy for them to rebuild it and they gave me a 2 week schedule...perfect ! Then I got a call saying that it would be better to get a new case rather than machining, some of the pressed races were worn and had play in them.

So I started to look for a case and then came across a complete 911/01 box for sale.....I should have listened to the warning voice in my head but I pulled the trigger and bought it sight unseen. I collected my old Gearbox and associated parts from German Transaxle and said I would be in touch. The "new" Gearbox finally arrived.....but as soon as I opened the box I noticed a big crack around the starter motor housing !!







Speaking with the seller he put it down to sloppy FedEx shipping! Around this time I got in touch with Jeff Gamroth of Rothsport racing, I had met him in passing at the Emory campout afew months earlier and he had come out with us on one of the Sunday morning drives. The work that Jeff and his team do is amazing and the shop isn't too far away from work:

http://www.rothsport.com

I took the two gearboxes to Jeff and immediately he told me the "new" Gearbox was junk..."the only way that can crack is from a rear end impact"...Jeff is a straight talker, but said he would be able to build something out of the parts I had:

"How much" I asked ?
"Well you need a Gearbox" he said and we left it at that...he did like the Vanagon though

Jeff called afew weeks later and said the Gearbox was ready...He had used another case and upgraded a lot of internals with stronger parts, installed a new diff, and replaced the synchros and sliders. All in all the Gearbox should now out last the car ! And the price ? Not as bad as I was expecting...especially as on collection it was sitting on a bench next to a 908, two 2.7RS , a Speedster and the two safari 964's :wink:



So all back together and went for a drive around the block...






Gearbox feels super tight and direct (as direct as a 911/01 can be) and just little blip of the throttle tells us that the carb work made a massive difference

BTW...The seller of the other Gearbox admitted that the "goods were defected"...I sent it back and he gave me a full refund. There is a moral there somewhere.


Onwards!
Chris

[jury]

On a lighter note...the clock now works. Those double Heuer stop clocks are so overrated

Keeping it Modernist thanks to Dieter Rams...




Also fitted a new Accelerator pedal, a beautiful engineered item from D-Zug. The feel is very different from original rubber pedal, much more on-off feel...the motion and feel is very direct. I also adding a slave spring, which is fixed to the Gearbox case. The spring hooks onto the Accelerator pivot arm and takes out alot of slack feel in the pedal linkage. I still need to dial in the angle on the pedal, there is a lot of options to get it in the right position but it feels good.

I will add some skateboard grip tape, just to give abit more underfoot assurance...

[jury]

A cold New Years day drive.

Idle set higher and Battery charging correctly. Gearbox feels great, as does the improvements made to the fuel delivery. Still afew tweeks needed and might fit a heavier slave spring on new accelerator pedal, but great progress made...








Still not 100% sure I have the correct Dipstick fitted...




Sounds good and pulls strong though...

VIDEO

[jury]

Solved the Oil issue...11 quarts later and all is good.

So all that was going ok, enjoying the car...getting out and about, meeting up with old friends...






And then.....Bollocks !!!






Could have been a lot worse !!!

[Ian Comerford]

The car is looking and sounding really sharp Chris. How much oil did you add though….! Was that a small fire in the filter?

[Ian Comerford]

The car is looking and sounding really sharp Chris. How much oil did you add though….! Was that a small fire in the filter?

[Ryan_Cunningham]

I love that dash!

[dreebs]

Yeah, that dash (and this whole build) is amazing!

[jury]

Originally Posted by Ian Comerford

The car is looking and sounding really sharp Chris. How much oil did you add though….! Was that a small fire in the filter?

About 1/2 quart from memory...Yes, there was a backfire in the carb, thankfully it was contained within the filter without too much damage. Could have been a lot worse !

[jury]

Carb rebuilt and all back together...Had an issue fitting the new Air filters (seem abit bigger than the originals) they started to bow so ordered a new set of Weber rain hats...After three incorrect orders, I eventually received the correct weber base plates and fitted with drilled wing nuts and "locking" springs.

[jury]

Now with added A E R O...

[jury]

The car was fitted with the Elephant racing polybronze bushings at the front and some "modified" (but can't remember why) Superpro polyurethenes on the rear.

They are pretty straight forward to do, just require abit of prep work and then some fiddling around with the supplied washers to get the correct amount of lateral play. All installed and then figure out the grease gun!

Got the trailing arms back in the same place +/-, but will do an alignment check once some new tyres are fitted.

[jury]

Whilst in there I decided to update the C.V joints. I had never been 100% happy with the original setup that I pieced together with used parts. So I got hold of some brand new C.Vs and axles, remarkable the difference in feel between the old and new. The original setup had alot of play in comparison ! ....



Only problem is that the 911 Gearbox is using 914 output flanges (smaller diameter, but compatible with the gearbox) in order to mate up to the 901 stub axles. The 914 output flanges have 4 bolts and 2 pins, so I made up new some pins and will press into place.

[jury]

After that I needed something fun to do...So got hold of a Repro Durant mirror, no original mirrors were harmed in the making of this.

But its true, if you think its difficult to see out of an original, try a repro...guess they are cheap for a reason !




Guess which race car the inspiration is taken from.....Clue: its Swiss :wink:

[jury]

Mirror update...Can now actually see out of it !

Talbot style bolted through the window frame...Considered painting it, but I am liking the integrated look









Also, again using the benefit of the roller paint job...Fill, Sand, Paint, Buff, Sorted

[jury]

Decided to revisit wrapping the exhaust manifolds (insert American accent - Headers).

It was a PITA first time around and this time was no different...Itching and frustrating, but happy with how it turned out. Still not 100% convinced on the benefits for a road car, but I do like the vintage race car look. The plan was more for temperature management rather than performance gains...










Will probably end up having them Ceramic coated... :roll: