my low budget dream car build

[rfloz]

Originally Posted by DHE11

Aside from a nice touch of personal customisation, your weight savings holes should prove functional as well....

My previous car had the deep 964C2 style rear bar and light assemblies, and it was amazing how much air gets trapped back there. Video footage and all the dirt streamlines in the wet show up the various air paths trying to find any way out....
Can see on the newer 911 race cars they basically have nothing behind the rear wheels now.

Yes - I saw oil temp reduction just waiting in a/x run lines

[chrisbalich]

i wasn't the most productive, but i managed to get a little something done tonight.

here's ~$15 worth of hardware and JB Weld to stick holes on holes. lol


16 screws JB Welding to the speedholes
i'm super stoked on how straight i got these little puppies sat on this piece.


then because i was on a hot streak, i banged out this fender lip real fast.
#punintended


i came back inside the house and found Kelly cocooned on the couch watching Big Brother. (her favorite) there would be no sweet car projects nor places to execute those builds were it not for her. #bestwifeever

[chrisbalich]

i'm glad to say that the JB Welded screws hold tightly enough for me to use a ratchet to screw on the nylock nuts. i figure that means the 16 of them should have no issue holding up that sub-8oz panel assembly. hopefully the heat/vibration doesn't rattle them off. but if they fail, i doubt they all fail simultaneously and i'll be able to rescue the panel before things get too bad.

[bgyglfr]

I live in Illinois about three hours from you. I get to Indy about once a month or so. I'd be happy to stop by when I'm in town and lend advice, a helping hand or just have some beers and BS.

[DHE11]

Yeah, that isn’t falling off any time soon.....
(and when your looking for the last few ounces to get that weight target you can go back and remove half)

[chrisbalich]

Originally Posted by bgyglfr

I live in Illinois about three hours from you. I get to Indy about once a month or so. I'd be happy to stop by when I'm in town and lend advice, a helping hand or just have some beers and BS.

you'll have to BYOB as we never have the stuff in the house, but you're more than welcome to drop by and hang out. i'm ~30 minutes north of Indy. LMK

Originally Posted by DHE11

Yeah, that isn’t falling off any time soon.....
(and when your looking for the last few ounces to get that weight target you can go back and remove half)

i thought the same, but i want to be sure it A. doesn't fall off and 2. it forms nicely to the tail panel.
maybe after it's 'trained' a bit, i'll feel more comfortable using fewer screws.
plus i can trim each of the screws down probably by about half. i got them a bit longer than absolutely necessary in case i need to use any washers as spacers to get it to sit nicely.

[chrisbalich]

i need some help. Google isn't turning anything up and i haven't found it here or on Rennlist.

does anyone know anything about this oil cooler?
it doesn't appear to be the carrera cooler at all and it's clearly not the trombone or brass coolers.
one day, i'll upgrade to a FMOC. but for now, i just want to know what i have.

[bgyglfr]

It's a turbotrol. Aftermarket I believe but they are good oil coolers.

[chrisbalich]

Originally Posted by bgyglfr

It's a turbotrol. Aftermarket I believe but they are good oil coolers.

awesome. thank you!
idk why i struggled to find that out. a quick google of turotrol pops up a million pics and links.

[Tremelune]

Originally Posted by ADDvanced

Fiberglass fenders never fit right or look right; the radii on edges are always fat/cheap looking. Steel is real!

This is pretty old-fashioned. I challenge anyone to see the difference on a properly-prepped Getty fiberglass setup than steel.

The cheap looks come from cheap parts and cheap installs.

[computiNATEor]

This is awesome work! Just wanted to say something so I get the daily emails

[bluebullet]

Good stuff. Glad to see the progress coming along!

[chrisbalich]

Originally Posted by Tremelune

This is pretty old-fashioned. I challenge anyone to see the difference on a properly-prepped Getty fiberglass setup than steel.

The cheap looks come from cheap parts and cheap installs.

all true. and i've seen plenty of cars that use poorly assembled/installed fantastic parts that looked cheap.

Originally Posted by computiNATEor

This is awesome work! Just wanted to say something so I get the daily emails

i'll try to make sure they're worth something. unfortunately for both of us, tonight is not that night. more below.

Originally Posted by bluebullet

Good stuff. Glad to see the progress coming along!

Thanks!

so this weekend wasn't super productive.
i spent friday night with the Mrs. then drove to Cincinnati. early saturday, we got up and drove across most of Indiana to swap some cars with my friend. i didn't get home until late in the afternoon saturday. so i tried to be productive with my limited time. i took an hour or two and drilled some holes in the tail panel of the car to fit the studs that i bonded to the speedholes panel. then, i painted the panel to prevent rust. while i was fine-tuning the fit, one of the studs came off. :/ frustrated, but not beaten, i pressed on. i roughed the panel deeper and re-bonded the stud while i finished the tail panel of the car.
i plan to run the speedholes brushed, so i broke out a fresh red scotch-brite pad and went to work. *meh result*
so i grabbed a sheet of 320 grit and used the red scotch-brite as a backer.
*meh*
180
*meh*
120
RESULT!


...
except two studs popped off due to the limited side-loading on them from the brushing/sanding/scoring/whatever process. the JB Kwik isn't curing like regular JB does. so i'm exploring different bonding solutions. there's Super Alloy 1, 3M Panel Bond, real JB, Quiksteel, or i put holes in the speedhole panel to bolt through and admit a crushing defeat.

whilst pining my options, i decided to bring one of the doors up from the basement to see what i need to do to prep it for epoxy. i got the passenger door all the way into the garage and the power window conversion off before my brother in-law showed up. so that's it for the weekend. i got some disappointment and a lot of being off-task. i'll get pics of the wild electric window conversion thing tomorrow.

[chrisbalich]

so i picked up some new epoxy for the studs on the speedholes. the JB Kwikweld is crap. never got hard. i was able to scrape it clean off with a razor. so i cleaned the screws with the bench grinder and then roughed up the back of the speedholes with the same (wire wheel). measured and marked up the speedholes and tried some new epoxy.

it came with a mixing nozzle just like the body panel adhesive, only smaller. i did a chocolate chip sized dollop for each screw, set them in place, and then went back and added more to better secure the soon-to-be studs.


while that was curing, i started looking at the passenger door i'd brought up from the basement last week. i pulled off the outer wiper trim, the inner, the door handle, the limiting mechanism, and then saw that (dead weight) supplemental side-intrusion bar. a quick google search shows it's USDM only, so out it came. lol. if only it was that easy. turns out i have no cut-off discs for my dremel and the angle grinder is a bit overkill and way too big to fit. so rather than be an adult and wait til i had the right supplies, i drilled several holes in the bar right next to the weld and then cut it with a hacksaw blade. not the whole hacksaw. just the blade. i have a fantastic blister/avulsion where the blade cut into my index finger. but i got the bar cut and it's out. i'll weigh it and get pics this weekend. i need to change a balljoint on Kelly's A3 and mow and i'm free to work on the 911 for the balance of the weekend. so hopefully i can get some decent work done and maybe get the rest of these panels in primer. (that's super optimistic)

[75 911s]

Thought those safety bars were added to grey market cars or imports. Or what year did they start? Pretty sure mine doesn't have 'em. I did picture you sawing away with the blade only. That made me laugh. Actually gave me an idea. My fenders are tack welded on, a dremel with cutting wheel wont fit, but just a hack saw blade will! Thanks for the idea! :-D

[chrisbalich]

Originally Posted by 75 911s

Thought those safety bars were added to grey market cars or imports. Or what year did they start? Pretty sure mine doesn't have 'em. I did picture you sawing away with the blade only. That made me laugh. Actually gave me an idea. My fenders are tack welded on, a dremel with cutting wheel wont fit, but just a hack saw blade will! Thanks for the idea! :-D

my car is a ROW car. and that's what i'd read. but i'm not 100% sure. there's a lot of lore out there about what options/add-ons came in what cars. but i know i had/have them. so they're coming out. no airbags, no abs, no side-impact crash-bars. we die like men in my cars.

if you're going to use the hacksaw blade only, i advise the use of a tough/heavy glove on the sawing hand. for as anti-climactic as this hole in my finger looks, it hurts like a real bish.

[1979-930]

Sorry I'm too late. Since you are not welding the studs you should have used elevator bolts for that panel. There is more area for the epoxy to hold.



I guess there is always next time if they don't hold...

[chrisbalich]

Originally Posted by 1979-930

Sorry I'm too late. Since you are not welding the studs you should have used elevator bolts for that panel. There is more area for the epoxy to hold.



I guess there is always next time if they don't hold...

dang! those would be perfect. i could just lay a lake of epoxy and hold those puppers.
hopefully it doesn't come to that. but if it does, i may drill little holes in the flat so i can have little epoxy 'rosette welds' to add strength.
there's nothing quite like doing everything the absolute hardest way.

[chrisbalich]

i have 11 pics to post, so i reckon this is gonna be two posts.

here is where the speedholes debacle presently is. it's been mounted for 2 days to see if the epoxy is going to hold. i've been pushing the car out into the sun every day to see how it holds. #babysteps


i wasn't sure where to put the decklid when i brought it up from the basement, so i just set it in place for S&G. #playdressup


did a little housekeeping. tidied the garage and then started my whiteboard over from scratch. i'm trying a new thing where i only put a few things on it at a time. i'm hoping to keep from getting overwhelmed. there's a lot to do and if i think about all of it, i just want to go ride my bike and not work on the car.


i've sanded every panel i've taken off except for one. (it's getting a different treatment, so it sits for now.)
here's some junk i sanded down with 80grit in prep for epoxy.



stay tuned for the next post where things get weird.

[chrisbalich]

cont'd

looks like speedholes are going to be a theme with this build. although not all of them will be visible...


and the aftermath


this heifer is where the weirdness actually presents.


i started with 40 grit to knock down the paint, but an edge came up kinda wonky so i put a razor under it and lo & behold...i can strip the red in big ol' scales/flakes. so i was able to do the whole panel with a razor. then i gave it a once over with 120grit and chucked it in the backyard. (not an exaggeration)


same story with the hood. this first pic was taken before sanding at all. just scraped down with a razor.


and its aftermath


my fingers hurt like a bish and my skin feels like there's an extra layer of leather on them. between the razor and DA all day, my hands are wrecked. *including where some paint shards jammed up under a fingernail hard enough to bleed pretty hard. there was swearing and stamping of feet.*
once i sort out how to prop everything up, i'll get it all in epoxy.
man, i can't wait for the day when everything is grey and sealed and i can close this chapter.