Rebuilding a Porsche 959

[felix83]

Wow. Just read this thread in its entirety - truly epic stuff!
I must say that you, Roar come over as a very down to earth guy and I applaud you for saving a 959 that otherwise probably wouldn't be saved.

Sjikkelig go prosjekt - fortsatt lykke till!

[Moriarty]

Just been through all the pages...just one reaction: whaouuuuu!
Great project that needs a lot of motivation, keep the good work, all my supports from France!

[iiXii]

Creazy post !

Thank youuuuuuu

[roarmac]

Hello guys.
Some progress to report.
The wheels are soon repaired. All the wheels have been sent to a magnesium guy for check, he is even able to repair the very damaged one, rear left very nice, that means that I actually have spare

The roof and the left quarter is comming together.
At the moment it is only "patched" up to be able to make a mold and than new Kevlar/fiberglass combo will be reinforced and the "patch up" removed.
Here is a picture




The roof is not perfect yet, but we got some dimensions yesterday that was of great help. The roof is also missing the flange where it joins the quarters, but that will be fixed before the mold is made.


Regards,
Roar

[roarmac]

Here is a updated picture of the engine. New muffler, repainted pulley to the right for the servo...
The fan housing is also new


Roar

[roarmac]

Hi guys.
Here are a fem more pics off the progress.




The rear spoiler is brand new, newer used but painted for a red car. The maroon red bumper is bought off a part seller in Germany of one car that has been taken apart..

Regards,
Roar

[Tooth911]

Dude!

[fanaudical]

[Festive_Zombie]

Love it! Keep up the great work!

[Racerbvd]

I just wanted to Thank you again for sharing with us your project, what a glimps into a car very few have seen in person and fewer have seen the views that you are providing, thanks, and WOW!!!

[roarmac]

Hello Guys.
Happy you all like it. Im also quite happy that we manage to get this car up and running, a lot of people have said it is/was not possible... There is still a long way to go on other areas, but as far as the chassis goes we are getting very close to get it complete.

A great thanks to Wayne, a good guy in Canada and several helpers in Germany

Most people would have been happy with the products repaired as they are now, but we will make molds of the roof and rear left quarter and lay it up again with new kevlar/fiberglass to get it 100% in accordance with Porsche specs.. The whole idea from Porsche with the kevlar was to drop weight and maintain the strength using the Kevlar, and therefor we are not repairing bits, making new and cutting away damaged areas.

Here are the pictures before the mold taken:
Notice the joining area where the roof meets the quarters, this is the way it is done originally to be able to join the parts with blind rivets in addition to gluing the bits together. After is is filled with a Kevlar strip and primed and filled.








Next step as the mold is complete, will be to lay up the new bits and prep for painting.

That was all for now.

Regards,

Roar

[roarmac]

Hi

Here is a few pics of the mold process of the roof. If somebody out there needs a new roof here is how to do:
I can also be helpful with making roofs if somebody needs one. Not very many though that needs a new roof is there???






Regards,
Roar

[Moriarty]

Thanks for sharing, amazing work for an amazing car !
All the best from France !

[Uncle]

I love this thread. Every time I see an update I get a little smile and look foread to seeing what is going on.

[roarmac]

Hello guys
Things are moving on and the roof and left rear quarter is complete.
The finished parts are not trimmed yet, just put on to show how it turns out.

The parts are laid up in accordance to Porsche spec with 5 layers. One layer Kevlar/aramid in center and two fiberglass layers on inside-outside of the Kevlar.
Weight 150-250. The roof is made with using parts of the original to keep the originality. The center off the roof is made in a sandwich with foam to get it as strong as it is supposed to be. I thought this was sandwiched with Nomex, but that is not the case...

Pictures says more than words....

[totle]

Great update Roar:-). Soon to be shipped back to Norway:-)
Can't wait to see this car in person:-)

[hightuned]

Wow, thats about the most impressive restoration ive ever seen, not many ppl would be able to pull that one off as you cant exactly call you local junkyard and ask if they got any 959 parts on laying around!!!

[roarmac]

Hi.
I could need some help with the paint process on the 959. Maybe some off you know and also have paintedkevlar/Fiberglas before?
Type of primers/fillers and so forth.

Thanks,
Roar

[jsveb]

I would get a hold of porsche962 here on pelican.

[roarmac]

Hi guys.
We are in the last phase of assembling. The car is back on the jig to verify all the dimensions once more before all parts are put on permanent and the car is painted...

Here is latest