PMB Performance - Project 914 ORV!, Yup, we're building a 914 for Utah's backcountry... Options

[Eric_Shea]

We've been playing with this one in our spare time. I don't think I ever put an official thread up here on the site so, here goes!

This piece of crap will soon become "Project 914 ORV". Actually what looks pretty bad on the surface; is pretty bad "on the surface".

As many 914's go, someone tried to make this one something it isn't. It isn't a "slant nose" no matter what you do to the fenders. And, I don't care how many Miami Vice episodes you've watched, that rubber whale tail thingy and the rear reflector are just plain "wrong".

But wait... Speaking of "just plain wrong", were going to carve this late model, big bumpered version of of 80's lust into a high-rise, fiberglass skinned, tubed tub that's ready for Utah's backcountry. That's right; White Rim Trail here we come!

Fear not, we're still thinking "all things vintage" so, we'll be pouring over factory rally pictures and builds to make sure we can learn all we can from the engineers at Porsche who went before us.

Here it is as it arrived:

(IMG:http://www.914world.com/bbs2/uploads_offsite/fbcdn-sphotos-d-a.akamaihd.net-1110-1396236965.1.jpg)

Mmmm purdy huh? (IMG:style_emoticons/default/wub.gif)

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Time to get busy. Shovel loads of crud came out of the trunks and interior:

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Bummer... (IMG:style_emoticons/default/sad.gif) (IMG:style_emoticons/default/lol3.gif)

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Getting there:

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Buuuu-Bye:

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Ooooh, the comedy never stops when you're working on a 914. Farm and Fleet tractor implement lights silly-coned on for turn signals! Yee-Haw!!

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Rio inspecting the progress:

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Off come the body panels. Special thanks to Elli-rot who went before us. He sent a bunch of pictures of his Dzuz fastener locations and offered advice on where to put them as we cut the panels off. Here you see pictures of his cars taped to the body as we taped and cut. (IMG:style_emoticons/default/wink.gif)

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That there's a good 1 1/2" of Bondo. (IMG:style_emoticons/default/lol3.gif)

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Done:

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Nice solid tub is what we were looking for and it appears that's what we got.

(IMG:http://www.914world.com/bbs2/uploads_offsite/scontent-a-dfw.xx.fbcdn.net-1110-1396236970.12.jpg)

More panel cutting:

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Here you can see what we're aiming for. All of the QRS panels from Jeff are laid on the car in a mock assembly. Already looking 100% better! Next it's off to sand and soda blasting.

(IMG:http://www.914world.com/bbs2/uploads_offsite/fbcdn-sphotos-c-a.akamaihd.net-1110-1396236971.15.jpg)

[Eric_Shea]

I've decided to use our "PerformancePolyâ„¢" brand of bushings on this project. These are the hardest durometer poly bushings available and can withstand over 10,000 PSI.

I can think of nothing more brutal than Utah's back country for a full on acid test. This should silence a few. Poly bushings get a bad rap because most units sold are the softer durometer versions and, yes, those do compress and fail, and squeak over time.

These have been honed on our lathe with an adjustable reamer set to the perfect size of our freshly plated shafts. Here we're taking the face down so the knurled end of the shaft protrudes beyond the bushing just enough to grab the inner ear and outer mount.



Here's a test fit on the shaft and, you can see the knurled section "just" protruding from the bushing. This is the look we'll be after once they're mounted.



This bushing is being test fit into the arm. Notice the grease ring cut inside. We'll measure this and mark the arm off for a grease zerk here.



Here, both bushings are test fit onto the shaft. It's a perfect fit. No slop, in fact, it's a bit tight because, once the grease is added, the nuts are torqued to spec. (over 100lbs.) and a 1900lb car is riding on top of them, they will spin easily and be totally noise free.



What's a 914 without a little "Wonder Glue"? Better known as JB Weld...

These bushings were twisted in and stayed over the weekend allowing the epoxy to set-up properly.



Using the drill press, a perfect 5mm hole is punched through right in the middle of the grease groove we cut in earlier.



A 6x1 tap finishes things off nicely here...



Here you can see how it lands in the grease journal.



..and, the zerk.



And here's the end result. Notice the knurled end of the shaft standing just proud of the bushing face. Too much and the arm would slap around with lateral movement. Too little and the bushing would bind on the body after the shaft was torqued to spec. I like how the beehive bleeder caps snap over the zerks!



Longer studs were pressed in the rear hubs to allow for the 930 spacers.



The hubs were pulled into the arms and topped off with new 914-6 rotors which match up with the mounting holes on the 911 hubs.

This project should never require a vented rotor in the rear so... why bother. Special calipers are on the way. Stay tuned.



The Stub Axle and castellated nut are in place and ready to go on.