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> Another damn 3.6 project............., finishing touches
East coaster
post Sep 16 2006, 01:18 PM
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I forced myself to quit driving my car for a few minutes and work on one of the last pieces of fabrication. I took an old style deep rear valence and modified it for my car.

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I flared the ends to match the GT flares and then cut out a section in the middle for my exhaust exit (and welded up the old side exit!) and welded in some spare engine lid grill work to finish it off.

I cut out an area the shape of a continuation of the rear bumper line for asthetics, I think it works?

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Porsche Rescue
post Sep 16 2006, 01:20 PM
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Very well done. Looks great.
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East coaster
post Sep 16 2006, 01:23 PM
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Here's the flared ends. I used a combo of divinycell foam and fiberglass to create the flared ends rather than beating the crap out of the stock metal and trying to stretch it. A man needs to know his limitations (IMG:style_emoticons/default/biggrin.gif)

It's strong, fits well and the car will never know!

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East coaster
post Sep 16 2006, 01:25 PM
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Gratuitous money shot:

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dekman
post Sep 16 2006, 02:25 PM
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Beautiful job!!!! (IMG:style_emoticons/default/clap56.gif) Can I ask what you did for sheet metal around the 3.6?
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East coaster
post Sep 16 2006, 06:41 PM
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I modified an aftermarket set of 914-6 sheet metal. I think my thread for the mods might be in the "classic threads" section. You have to fab some metal for the area where the 914-6 stock oil cooler goes, as the 3.6 doesn't have one and some material needs to be added to the front sections due to the difference in cam drive covers.
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East coaster
post Sep 16 2006, 06:46 PM
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Here ya' go: http://www.914world.com/bbs2/index.php?showtopic=10558

Some of the pics are missing though.......not sure why. I think I still hav'em if you need'em?
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PRS914-6
post Sep 16 2006, 08:25 PM
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Here's mine...
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brp914
post Sep 16 2006, 08:51 PM
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do you have a shot from underneath handy? If I recall, you're running a wevo/915 and I thought that would make a center exhaust a challenge. How do plan to use the car now? Are there roads in your area where that thing can stretch its legs a little?
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Joe Bob
post Sep 16 2006, 10:48 PM
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Nicely done...more pics....
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dekman
post Sep 16 2006, 11:42 PM
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Yes...if you don't mind, I would like a set of photo's of your sheet metal modifications. They would be very helpful. And I went through all your build pages....incredible job...meticulously done! Thanks...... (IMG:style_emoticons/default/thumb3d.gif)
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MecGen
post Sep 17 2006, 04:56 AM
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Hey

I like it ! (IMG:style_emoticons/default/smilie_pokal.gif)

The lines work realy well, the color is sweet. All and all a nice looking teener $$$
Good work

Later

(IMG:style_emoticons/default/beerchug.gif)
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East coaster
post Sep 17 2006, 05:24 AM
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Yeah....the 915 wevo makes a horizontal crossover type muffler a challenge. I started with an aftermarket 911 muffler (don't know the brand?) and I had to remove a section from the rear to clear the trans. I split a piece of 3" tube and added it to the rear of the muffler to regain some volume. The center outlet comes out of this new piece of tube. I also re-baffled the muff a bit to allow for the 3.6. I figured this muff was probably originally intended for a 2.0 -2.4 engine. It definitely breaths well and sounds wicked!

Here's a view of the muff to tranny clearence:
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Here's the outlet off the added section:
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East coaster
post Sep 17 2006, 05:31 AM
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Paul, Awesome job on the sheetmetal !! I didn't have the original 3.6 metal to steal pieces from, but that's a great idea! You should add that to the classic thread, I think it would be really helpful to others who cross this path. When I did my conversion there was very little 3.6 info on this site and to get info was like pulling teeth. I think it's great that anyone thinking about a 3.6 conversion now has some resources here refer to.

Nice job!!
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Jeroen
post Sep 17 2006, 06:00 AM
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awesome job!

I love the way the grill in the valance follows the indention on the bumper
nice detail where the grill (almost) meets the exhaust tip!
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PRS914-6
post Sep 17 2006, 09:44 AM
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QUOTE(East coaster @ Sep 17 2006, 04:31 AM) *

Paul, Awesome job on the sheetmetal !! I didn't have the original 3.6 metal to steal pieces from, but that's a great idea! You should add that to the classic thread, I think it would be really helpful to others who cross this path. When I did my conversion there was very little 3.6 info on this site and to get info was like pulling teeth. I think it's great that anyone thinking about a 3.6 conversion now has some resources here refer to.

Nice job!!



Thanks! I bought the 914-6 sheet metal and then hacked the hell out of it......sigh. However, with the one piece from the 993, it looks factory when bolted on now that it is powder coated.

For those doing this, start by bolting the side pieces on. This gives a correct reference point. EVERYTHING else has to be modified and some pieces extensively. It's not hard, but it is challenging and time consuming. By the time I got done, it took me a weekend. It's important to leave a 1/2' lip on the original pieces so you have something to spot weld to. If you place the fabricated pieces on the top of the lip when spot welding, you can't tell it's not original.
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PRS914-6
post Sep 17 2006, 09:48 AM
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On the muffler, that was very creative thinking and I like the look a lot. Ultimately, I'll go to a 915 after I blow up the 901. (optimistic thinking uh?) and will have to deal with that.

I was planning on a 911 muffler. I like the tucked up look without the noise. I prefer a quiet car and this part may prove to be challenging to get maximum HP without all the noise.

Compared to a stock 911, how is the noise factor?
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East coaster
post Sep 17 2006, 01:25 PM
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WHAT???

Sorry....couldn't resist!

It's a little on the loud side, but it's still hard to differentiate between intake growl and exhaust growl. The harmonic created by the two together is pretty loud. I also haven't added anything to the firewall yet. My stock backpad doesn't fit with the seats I'm running so I need to fab something. I'm thinking dynamat and then carpet. That will quiet it down some. I can hear the stereo pretty well if I want to, but I'm still at the "Schweet engine music" stage.

I was worried about restricting the exhaust too much with this muff, but my fears were unfounded! It has a nice low freq growl at low rpms, but when you kick the throttle and tach it up it sounds like an Indy car.......Awesome!!

I'd say it's somewhere between a stock muffler and supertrapps.
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East coaster
post Sep 17 2006, 01:28 PM
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Here's what the internal baffles looked like where I cut the chunk out of the muffler to clear the wevo (IMG:style_emoticons/default/sawzall-smiley.gif) :

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