my low budget dream car build

[chrisbalich]

Sneak peek at what I spent all day working on.


With the car being largely drivable, I need to sort out the giant forking hole in the front that just sucks up air...and water if I find myself in the rain.

[ian c2]

That cardboard could easily get ruined by the slightest bit of water .
Did you think about replacing it with a piece of aluminium ?

[Larmo63]

I'll take a bumper vent........?!?

[chrisbalich]

Originally Posted by ian c2

That cardboard could easily get ruined by the slightest bit of water .
Did you think about replacing it with a piece of aluminium ?

Anything is waterproof if you apply enough Aqua Net.

Originally Posted by Larmo63

I'll take a bumper vent........?!?

???

[Jonny042]

PS - if you raised the brake hose brackets 40mm IIRC you might be perilously close to them hitting the dust covers at full bump.

You didn't mention cutting the bumpstops, you can, and maybe should. It's also worth checking for suspension travel. You probably saw this, but it's pic of the Rot Rod (40mm raised spindles) with the torsion bars REMOVED:

[chrisbalich]

Jonny,

I cut one bump off the bumpstops, removed the dust shields behind the rotors as well as the steel dust covers over the shocks.
Apologies for the missed details in my original post.

[Jonny042]

Originally Posted by chrisbalich

Jonny,

I cut one bump off the bumpstops, removed the dust shields behind the rotors as well as the steel dust covers over the shocks.
Apologies for the missed details in my original post.

Yeah I removed the dust covers too. Mostly for weight savings, front and rear. I think I used an engine mount cup washer with the hole enlarged to replace the dust cover, so the strut still bears on the top bushing properly - otherwise it might pop through far enough to bugger up your hood.

[chrisbalich]

Originally Posted by Jonny042

Yeah I removed the dust covers too. Mostly for weight savings, front and rear. I think I used an engine mount cup washer with the hole enlarged to replace the dust cover, so the strut still bears on the top bushing properly - otherwise it might pop through far enough to bugger up your hood.

Ah ship. I guess I have something to do today other than apply Aqua Net to the cardboard airbox. I didn't even think about the need for a huge washer up there.

[Jonny042]

Originally Posted by chrisbalich

Ah ship. I guess I have something to do today other than apply Aqua Net to the cardboard airbox. I didn't even think about the need for a huge washer up there.

Something to look at, anyway - I'm going from memory. But I found this - looking at the diameters, I don't think you're in any immediate danger, and in fact might have stumbled upon a ride quality hack!

[obscene]

Originally Posted by chrisbalich

Sneak peek at what I spent all day working on.

Utah! Make two of those please and thank you!

[chrisbalich]

Originally Posted by Jonny042

Something to look at, anyway - I'm going from memory. But I found this - looking at the diameters, I don't think you're in any immediate danger, and in fact might have stumbled upon a ride quality hack!

Considering the way the shock bottoms out on the bushing, I agree that I'm not in any immediate peril. I'll jack the car up in a few and shine a light up there to see if it looks sketchier than I'm comfortable with. But I really think it'll be ok after looking at a bunch of replacement bushings for the upper camber mount.

Originally Posted by obscene

Utah! Make two of those please and thank you!

I need to confirm it works first.
...and then still no. Too much work for something so unsightly. It's one thing to run jalopy bits on my own car, but quite another to try to sell them. Maybe one day when I have a TIG machine or learn to manipulate fiberglass. Maybe.

[chrisbalich]

I spent pretty much all day yesterday and up til now today working on this contraption. The objective was to direct water out of the car and as an added benefit, direct air where it's most needed in the car. I reckon by this time tomorrow, I am officially out of excuses to not wash it.

The CAD piece now remade in aluminum. All aluminum construction (aluminum rivets). Guaranteed to leak like a sieve. (no TIG machine)


Aluminum box detail shots




Mock-up of rain flys to keep water out of vents


Glued up with polyurethane adhesive. Should provide strength to hold it all together and seal it up nicely. If this fails, I will be seriously unhappy and then probably move on to windshield adhesive...which is phenomenally sticky and runny and messy, but always holds.


Rain flys now in aluminum. Riveted down. Sealed with polyurethane to prevent water intrusion.


In situ. Drain is made from a grommet I had laying around, some plastic hose connectors, and some clear tube. (Every single part of this air box is stuff I had laying around. ZERO trips to the store.)


I made these little guys from some leftover rain fly material and some hose clamps Porsche left in my car where I think they intended for there to be heater hoses. Hoses were not received with car. Maybe they dried up and blew away, maybe they were removed. 50:50


SCEET hoses added and clamped into place and now I have 'direct drive AC'.


Hoses directed where needed most. On the boys.


Now if we can convince Bryan and Tony to make up some Kool'n Ducts that have round 60mm inlets, I'd be willing to give those a shot and maybe class up the interior of this hog a little.

[baloo]

Can't wait until you have your car up for sale!
Get it sorted, then sell it to get your next project.
Do not drive it. Something bad will happen.

[Trackrash]

Originally Posted by baloo

Can't wait until you have your car up for sale!
Get it sorted, then sell it to get your next project.
Do not drive it. Something bad will happen.

Today the guy in front of me hit a deer hard enough to send it 12 feet in the air over his car. I had to swerve to miss it, then the guy in the Mercedes behind me had to swerve to miss me. All on the way back from the dentist.

Originally Posted by chrisbalich

I spent pretty much all day yesterday and up til now today working on this contraption. The objective was to direct water out of the car and as an added benefit, direct air where it's most needed in the car. I reckon by this time tomorrow, I am officially out of excuses to not wash it.

Aluminum box detail shots

I have been planning on doing this to my car for decades. The thing is I never drive in the rain and it is nice to have the vent in the middle of my dash blow air in my face.

Originally Posted by Jonny042

Something to look at, anyway - I'm going from memory. But I found this - looking at the diameters, I don't think you're in any immediate danger, and in fact might have stumbled upon a ride quality hack!

Have you considered welding gussets to reinforce and stiffen your strut tube? Makes a difference IMO.

[chrisbalich]

Originally Posted by baloo

Can't wait until you have your car up for sale!
Get it sorted, then sell it to get your next project.
Do not drive it. Something bad will happen.

I'm not known for having great luck, but it's generally not that bad.
I sincerely hope you're not a psychic.

Originally Posted by Trackrash

Today the guy in front of me hit a deer hard enough to send it 12 feet in the air over his car. I had to swerve to miss it, then the guy in the Mercedes behind me had to swerve to miss me. All on the way back from the dentist.



I have been planning on doing this to my car for decades. The thing is I never drive in the rain and it is nice to have the vent in the middle of my dash blow air in my face.


Have you considered welding gussets to reinforce and stiffen your strut tube? Makes a difference IMO.

Gads! That's not scary at all.

I don't plan to drive in the rain. But I also like to go on road trips and live in the Midwest. There's almost no avoiding it. So better to be prepared than to carry around a roll of duct tape to close that vent if rain moves in.

I really did consider it. It would be easy enough to go back and add if I find myself doing more track work than I currently expect to do. I have started stockpiling bushings for the future suspension overhaul. (more bushings, shocks, and TBs still need purchasing) If I'm going to make any [more] big changes, it'll be at that time.

[obscene]

lol I never drive the 911 in the rain, but every time I drive the 911 it rains.

[obscene]

Originally Posted by chrisbalich

It's one thing to run jalopy bits on my own car, but quite another to try to sell them.

oh you thought I was gonna give you money??

[chrisbalich]

Originally Posted by obscene

lol I never drive the 911 in the rain, but every time I drive the 911 it rains.

For real.

Originally Posted by obscene

oh you thought I was gonna give you money??

LOLOLOLOL.
(actually LOL'd)
Good morning, my man.

[ADDvanced]

Driven mine in the rain plenty of times, no big deal, until one day it happened. Snap oversteer. Didn't lift, countersteered correctly, WHEW. Gets you a shot of Adrenalin tho if you aren't expecting it.

[chrisbalich]

I did the unthinkable last night.
I added ~6lbs of sound deadening (Noico 80mil) to the backseat seat back, parcel shelf, and backseat seat pans.
I think with the tub having no sound deadening at all that it's acting as a big bandpass box when I drive. The volume isn't crazy loud, but I think it's generating enough 'sound pressure' to cause my head to hurt after a few hours. I'm hoping to mitigate this with the sound deadening. I have 7 more lbs of the stuff, but I'm not super keen to add any more weight nor do I want to pull up carpeting to put down deadening.
I'll update after more miles this weekend.
Stay safe, everyone.