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)
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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]

Friday, a friend of mine came by the shop to help me out with removing the damaged front clip off the ’67 Square. Originally I was going to just run what I had and body work it, but I soon discovered that the clip was pushed back almost ¼” on the drivers side making it all not square underneath and preventing the fenders from mounting properly. What I have planned for the front suspension requires it to be 100% square, so the old had to go.

We began by removing the fenders. Then made a series of careful measurements so as to ensure repeatability from one side to the other. Then marked the front-end with cut lines. Then taped the cut lines and cut along them with a cut-off wheel.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1363738722.1.jpg)

Won’t be driving fro a while until this gets back on. How’s that for adding some motivation??

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I’ve currently got about ½” overlap which will be slightly trimmed to about ¼”. Then I’m going to flange the rear side with a flanging tool so I can properly overlap and weld the pieces back together on either side. This method should make a super strong re-connection.

Had to stop on a clients car early due to waiting on a part, so I put the rest of the day to good use.

I prepped the edge of the cut on the body with a 2" wheel down to bare metal. repeated this to the replacement clip section. Then brought out the flanging tool which is air driven. It makes a nice off-set flange so you can slightly overlap metal to be welded. Makes for a nicer joint in the end and is easier to fit pieces too.

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1363738722.3.jpg)

Once the body was flanged, I test fit it and double-checked the key measurements. Then triple-checked them again. Then tacked it in place. . .

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1363738722.4.jpg)

Then mounted the hood for a test fit before final welding. . . PERFECT!!

(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-9730-1363738722.5.jpg)

Now I have to finish weld both sides after I get another bottle of shielding gas.