OT: Working on my shop car, The wagon Porsche never built. . . Options

[aircooledtechguy]

I've had a long term project going now to turn my '67 Squareback into my shop car. While I love driving my 914, it has limitations as a daily parts hauler. I love old styling with new technology and updates, so my goal is to turn my humble Square into the wagon that Porsche never made. I want it to drive and handle more like a Porsche than a VW wagon and it's got to be a true "Sleeper" (not a real problem; since it's a wagon). (IMG:style_emoticons/default/shades.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1324689630.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1324689631.2.jpg)

This has been a 4-5 phase project.

Phase-1 - Convert it to Porsche 914 2.0L motor. Make it physically adapted to the car and running MS2 w/ Ford EDIS ignition. Get it tuned to be a daily driver. DONE!!

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1324689631.3.jpg)

Phase-2 - Make the motor look good and freshen it up with new P&Cs. The heads were freshened only about 2K miles before I got it, by me when it was in a clients 914 that he converted to Subie power. I noticed that once I had a few miles on it myself, it was using a bit of oil. So I upgraded to a new set of 96mm P&Cs. So now it's a 2056.




I had my local powder coater do all the tins in black and the plenum and runners in grey for a stock look. I'm running T-4 H/Es with a modified bus header and a Summit Racing Flow Master clone muffler. So I had those ceramic coated in black so they are not attention grabbers from the back. This car is a sleeper (IMG:style_emoticons/default/happy11.gif)



DONE!!

Phase-3 - Convert the rear suspension to the later style IRS and install a Porsche 923 trans out of a Porsche 912E. The rear suspension is DONE!! While at it, I upgraded it with 914 rear brakes, urethane bushings, adjustable spring plates and a rear sway bar. (IMG:style_emoticons/default/driving.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1324689632.4.jpg)

Since the trans is taller than a stock 4-speed and cutting into the car can't happen due to rear seat issues. I gained the 1.5" I needed by spacing the body off the rear suspension with spacers. So here I sit, on the final leg of phase-3. I now need to couple the motor/trans and lift it into it's final place and fab rear engine hanger mounts for the rear bar. It's late and I'm tired. . .

Phase-4 - Front suspension upgrade. Currently in-work

Phase-5 - Paint so it doesn't look so crappy, though it does add to the "sleeper" persona. . .

Stay tuned for more later. . .

[aircooledtechguy]

As I log more and more miles onto my shop car, I have found that I miss the larger 15 gallon tank on my 914. I drive 40 miles round trip a day minimum and find that because of that, I need to fill up before the weekend if I fill it on Monday. Also, the Porsche 911 fuel gauge works on a slightly different oHms range so when full, it only read about 7/8 full. Currently I'm getting around 27mpg in mixed driving. So I decided to do something about the lack of range and the incompatible sender.

I have had a spare tank for years, so I carefully cut it with a cutting wheel (after ensuring there were no old fuel fumes present) and cut off the original filler neck. This is the tank "on the half shell"

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1340225734.1.jpg)

I added 2 "L" shaped pieces that were 4.5" tall into place and welded them into place.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1340225735.2.jpg)

After everything was fully welded, I placed the top back on and welded that into place. Then I brazed a custom filler that will fit below the hood like stock. I also brazed in a fuel return nipple to the bottom as well so the plumbing can finally be correct for the MS2.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1340225736.3.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1340225736.4.jpg)

Now I need to coat it with POR-15 tank resin to ensure the rusted areas are stopped AND to ensure that if there are any small pin-holes in the welds, they will be permanently sealed. Then a black paint job and undercoating to make the outside look the part.

I should also mention that another reason for this was to better balance the car and up the weight a bit over the front wheels for better cornering (she pushes a bit in the corners like my 914 does when the tank gets below 1/2 full). I will be giving up a good portion of my frunk, but it's a Square, so room for crap is no big deal and I never really used the frunk anyway. (IMG:style_emoticons/default/shades.gif)