Palindrome 914 Build Thread, now on the chassis jig Options

[nathansnathan]

Nice job on the mezzanine! Must be nice to have some more room now. Speaking of which I'm about to start on my mezzanine this weekend. Are you going to enclose the top part in to keep dust out? (IMG:style_emoticons/default/beerchug.gif)

Thanks, Derek. I am pretty happy with it. (IMG:style_emoticons/default/piratenanner.gif)
I've oiled the joints and don't notice much movement when I'm doing my dance. (IMG:style_emoticons/default/biggrin.gif) I am thinking of putting in cross braces in places to tie it together, also of constructing caster mounts. (IMG:style_emoticons/default/happy11.gif)

The plan as far as enclosure is to divide the 2 halves of the shop during the sanding and primer stage with a heavy drop cloth curtain.

Currently I'm in the process of putting up the containment chamber on its own this time, need to make room by the cabinet (make the materials storage rack so I can slide the workbenchh down?) so I can blast the my valances and rockers, backs of bumpers etc.

I had been waiting the last 10 days for the parts from cyberweld, some mixup at my mailbox. They do have hookas for sale right in the place, the pack & ship.

Finally got the back caps, the small ones they sent me were wrong, were for the 17 torch instead of the 9 so pictured are the medium. Both of those are #7 cups.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305947534.1.jpg)

I hooked up with some weld backing options also, these from Eastwood. The triangle is my favorite so far, used it a lot for the inner inner long.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305947534.2.jpg)

During the wait though to do more welding, I've been detailing the outside of my engine case. Various methods employed have included a bit of acetone with lots of cotton swabs and paper towels, a bit of paint thinner and a brush, simple green some.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305947535.3.jpg)

Still coming along. I won't be able to finish until I put it on the stand and that I won't bother with until I've modified it. I've purchased this yoke:
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-11782-1305947535.4.jpg)
I have 2 of these coming.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.mcmaster.com-11782-1305947536.5.jpg)
I need to go to Industrial metals to get a cross beam for the front of this fan shroud murderer.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305947536.6.jpg)

Besides that, I've been blasting a piece or so of the tin each day.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305947537.7.jpg)
It does take awhile, the compressor is always running. (IMG:style_emoticons/default/smash.gif)

[nathansnathan]

To update, it was definitely fun, meeting up with David yesterday, checked out his roller at his work in Orange. I should'a brought my camera. I got a few minor things like a seat rail with the adjustment handle intact, I finally got a replacement for the oh-so-elusive door striker back plate casting that I'd broken off a tap in the original of, I cut out this replacement section of the drivers headlight side marker light wiring harness
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306129150.1.jpg)

the original had got a bit toasty at some point
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306129151.2.jpg)

The first thing I did when I got back was cinderblock mockups of the mahles.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306129153.7.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306129154.8.jpg)
I have been just looking at them fondly from time to time. (IMG:style_emoticons/default/drooley.gif) I got the lugs also, minus 4 of them. I need to find 4 more 38mm ones and I think I have 2 but need 2 more 19's for the spare I realize now. ... details. I'm pretty happy just to have them. (IMG:style_emoticons/default/biggrin.gif)
I got a really good deal on all of it, $420 discount. Thanks again to David for the the good times, like I'd said, my first 914 engine compartment outside my own. (IMG:style_emoticons/default/smile.gif) (IMG:style_emoticons/default/beer.gif)

[nathansnathan]

I've finished enhancing my engine stand and thought I would share. I just need to paint it, maybe shorten some bolts, and weld up the T handle to lock the yoke.

As I'd mentioned in the previous post, I'd ordered the 4 arm yoke off the guy on the samba, but did it off ebay actually. The description talks about how it will fit in a 'standard' 2 3/8 inch hole. The swivel on my empi knockoff stand is like 1 3/4 inch.

I'd thought about how easy it would be to just buy a new stand. So I talked to a bunch of people off Craigslist who were selling mostly the harbor freight stand and it seems that 1 the hole measures 2 1/4 inch? Maybe they were measuring it wrong...

With this complication, I went back to plan A, to modify my stand, and with a half day of work on friday for Memorial day, I was able to go to the metal place.

Getting started, the old swivel would have to go, thankfully.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769877.1.jpg)

I don't have pics of it specifically but I drilled off the old swivel caster that was at the front (honestly 1 supporting leg it had out front with a swivel caster! Check the pic, that had actually broken, the pin came 'unswaged' and the wheel had fallen off (IMG:style_emoticons/default/bootyshake.gif) )

Probably the biggest improvement was the stability added by the wider track front.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769878.2.jpg)

I decided to reinforce the joint between the vertical member and the lower part (previously just one bolt went through holding all pieces together, and then a flimsy cross brace above). (IMG:style_emoticons/default/aktion035.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769878.3.jpg)

I welded in through-tubes to reinforce both the members were the cross beam clamps down on them.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769878.4.jpg)
Welded, ground and sanded down
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769879.5.jpg)

And the yoke swivel enhancement. I found the perfect stuff in the remnants section, DOM tubing, or 'drawn over mandrel' there is no weld crease evident on it and it is quite hard, maybe 1021 the guy was saying, just short of the hardness of chromoly, but weldable as a mild steel. The stuff is thick walled!
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769879.6.jpg)
The bolts coming out are made of phosphor bearing bronze and there are 3 at 120 degree intervals at the front and the back. I'll put nuts to lock them in position. These take up the ~.015" play on either side; the difference in the id of the pipe and the od of the yoke swivel is pretty good but still a little play. 'I honed' the barrel of the yoke with fine sand paper. I think I may use way lube to check rust between. There is no drooping with the engine on it, no tendency for the engine to slide forward and out as before.

It's amazingly rigid. It feels awesome to be able to trip over it and not worry about having to 'catch' the engine or to have to leave it only in the 1 position that the yoke ears aren't strained being attached at only 2 independent points. I'm pretty happy with how it turned out.
Before: (note the tiny flat cross bar supposed to be bolted onto those tabs, is missing in the pic)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769879.7.jpg)

After:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769880.8.jpg)

[Beach914]

The Mahles are going to look great Nathan. They definitely look better on your car than that black roller. I think that the original color was L96D.

I've got some misc short Lugs that you can come over and pick through when you want.

Dave

[saigon71]

Nathan:

Great work man! I too am attempting a teener restoration in a one car garage...it is quite challenging sometimes! My ceilings are not as tall as yours though, so I had to pick up a shed that someone was giving away for parts storage.

Keep it up!

Bob

[nathansnathan]

Nathan:

Great work man! I too am attempting a teener restoration in a one car garage...it is quite challenging sometimes! My ceilings are not as tall as yours though, so I had to pick up a shed that someone was giving away for parts storage.

Keep it up!

Bob

Thanks, Bob. (IMG:style_emoticons/default/smile.gif)
Even as the parts are, I want them to be more 'out' so I can go over them in good order instead of just what I can get to. I can't recall where my glove box is... (IMG:style_emoticons/default/unsure.gif) (IMG:style_emoticons/default/biggrin.gif)

[nathansnathan]

Picking up here, update the thread.
I met up with David again, I'd been thinking about the fresh air vents on his roller ever since I'd seen a week or 2 before getting the Mahles. I got some pics this time.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307842265.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307842266.2.jpg)

The car is pretty crusty at the longs and jack point is floating in the rocker, lower firewall is bad, and floors. She was well done, and so with the fresh air vents being very good compared to mine
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591584.2.jpg)

Rather barbaric, I used a .40" cutting wheel on my 4 1/2 inch angle grinder.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307842266.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307842266.4.jpg)

I got the seam sealers all out with the heat gun and scraping screw driver, some rust in there but solid. I've started blasting and it's looking great.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307842267.5.jpg)

Will get a picture of after blasting and how I'm gonna install later.

[nathansnathan]

It does look rusty, but honest, just a bit of pitting.
Anyway, going stronger than that, (IMG:style_emoticons/default/smile.gif)
taking it to the next level, another car has come to me. (IMG:style_emoticons/default/beer.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307844936.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307844937.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307844937.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307844937.4.jpg)

It's funny, I realized after contacting the po that it was a guy I got a $2 door handle off of the first week I had my 914, Paul, who works at Rancho Transmission in Santa Ana. He is exactly 16 miles from me and I got it towed here this morning much more affordably than the first one, thankfully, though we did have to wait it seemed 2 hours for the guy to come on his 'day off'. Good stuff though to talk shop with a guy that knows about these things, or Volkswagens anyway.

Tuning was so so, probably would have idled if it got warm. It runs, I should add. The carb is, he told me, a real one out of an actual Pinto. The valves sound good though. I will have to do a compression check. Thinking I may get it rolling with that engine while I put mine together.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307845285.1.jpg)

Body is pretty crusty on this one, too, mostly down low though where mine is worse above, well except the hell hole, this one is the worse, the 420 car seems solid in comparison.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307844938.5.jpg)

A lot of the interior is there
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307844938.6.jpg)

It's got some really good stuff that came with it, all 4 rotors are German and new for 1. The driver door may be the one to use. The deck lids are better than both of what I have I think. It came with a a new carpet, black though, not sure how nice it is. The windshield is what I was looking for when I found it. I'd seen it before of course, but it really made sense more looking for a windshield. It looks to be very good, PPG. The top of the front bumper is straight and solid if I can get the chrome off. My plan is to d the bumpers the same as the wheels, in 'wheel silver'. I know it's not stock but I on' like the body color plan and have qualms about the re-chroming chrome route.

Other stuff that came with but probably won't use new-in-the-box 911 ate master cylinder, also in the box the front euro lenses, seemingly more brake calipers than the 4 (no brakes on it now), stainless soft line new. The backpad is pretty nice, early though as it's a 71.

It's pretty exciting just to have an assembled 914... to sit in. (IMG:style_emoticons/default/driving-girl.gif)
Just wait until the battery charges (it sit's in the trunk (IMG:style_emoticons/default/dry.gif) ), I'm ganna start it. Maybe tomorrow after the Classic (IMG:style_emoticons/default/aktion035.gif)

[dheming]

Nice score on the parts car. BTW, something like this is what I was talking about for a simple engine run stand: http://lainefamily.com/EngineStandProject.htm

[nathansnathan]

Nice score on the parts car. BTW, something like this is what I was talking about for a simple engine run stand: http://lainefamily.com/EngineStandProject.htm

You call that simple? (IMG:style_emoticons/default/biggrin.gif)
Here's a pic I had saved, he's got the fuel injection partially attached to it, too, 914 stuff there.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.eggscollective.org-11782-1308005510.1.jpg)

[nathansnathan]

This seems like a good place to talk about how I've got to get rid of the parts car as I'm still taking things off it, and it's not ready for the classifieds section yet.

I agreed with my land lord when I got permission to get it that I could only keep it for 3 months. So 1 month to go, I've got until September 1st.

Likely the shell will be mostly useless if it comes to calling the junkyard, as I would cut off what's good of the body just because it's good. A lot of it isn't.

The thing is I have to keep it rolling I'm thinking in order to get it towed or even trailered to a ..junkyard ... I'm a little nervous actually about it, whether I can just call someone to take away my cutup shell. Plus I would hate to think of the suspension and steering stuff getting crushed.

Maybe someone local has a yard or something. I'd sell it for less than most want for just the rack & pinion. We'll see how it goes. I'm just putting it out there.

[Mike Bellis]

If you have the title you can junk it. They can bring a flatbed and drag it. Take the suspension off. You could make a simple wood dolly on casters to move it around.

[nathansnathan]

About a week to go here and I think my landlord will be ok if I go long. Unfortunately I don't have the title. I've got 2 bills of sale from the past owners, so I'm going to cut up.

I've been busy preparing. I've got a reciprocating saw ready (IMG:style_emoticons/default/ar15.gif) and i've built a dolly. Once the donor is in pieces and the 420 car is more stable, I will put it on there as I need to be able to move it around to go forward.

Here are some pics of the dolly construction.

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1314420902.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1314420902.2.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1314420902.3.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1314420902.4.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1314420903.5.jpg)

[nathansnathan]

Other progress, I upgraded my air compressor. I'd got this old old Westinghose/ homemade jobber from some guy off craigslist a few years ago and I'd been working it to death with the blast cabinet. It is I think a 35 gallon. I'd been thinking about getting something better.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1314422026.1.jpg)

...so I found this on craigslist, got it from a tire shop in huntington Beach.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1314422026.2.jpg)

80 gallons, dual stage goes up to 175psi. It is actually made by the same company as the old one, as Westinghouse was bought by LeRoi, which actually makes this for Wayne. It is the real deal. The sort of overkill that I'd been looking for seems to come only in 3 phase, and so it was quite challenging to get it hooked up to work with single phase 220 power. I found a 5hp Baldor 220 single phase motor on eBay. It was not cheap, though I guess it could have cost a lot more for a new baldor motor of that size.

Anyway, this new compressor is a beast. I regulate it down to 90psi for the sandblast cabinet, and I can say that it does not EVER get below that. I can blast continuously and it will meet the demand. If I give it half a chance it will actually catch up and turn off.

I'd thought that the shortcomings of my cabinet were a lot due to it being not the recirculating type, but it is working a lot better with this bad boy, like it puts out a stronger 90psi than the other though I'm using the same gauge!. (IMG:style_emoticons/default/biggrin.gif)

(IMG:http://www.914club.com/bbs2/uploads/1313252010/gallery_21132_255_23387.jpg)

[Mike Bellis]

For future reference... There is a device called "Add A Phase". Available at most any electrical wholesale house. It uses an LC network to phase shift your house 220V into 3 pahse power. Small box, mounts on the wall close to your equipment. I've installed many in home garages needing 3 phase machines to function. Cost a couple hundred bucks... Easy install... 2 wires in, 3 wires out...

[nathansnathan]

For future reference... There is a device called "Add A Phase". Available at most any electrical wholesale house. It uses an LC network to phase shift your house 220V into 3 pahse power. Small box, mounts on the wall close to your equipment. I've installed many in home garages needing 3 phase machines to function. Cost a couple hundred bucks... Easy install... 2 wires in, 3 wires out...

I researched variable frequency drives, rotary and static phase converters, and I found that the rotary converter was the only acceptable way to do it. Upwards of 3hp it gets very expensive to do it right... though it may have been about the same. (IMG:style_emoticons/default/blink.gif) This is a true 5hp motor (IMG:style_emoticons/default/aktion035.gif)

[nathansnathan]

I've got some other 3 phase/ single phase stuff to figure out. It's a little easier than the motor as a heater can be wired in different ways. This crazy thing was actually out of a Chrysler plant. Running it single phase 220 will make it less effective than the 480 3 phase but it should still be quite effective. I've read that getting the paint to off gas is the secret to a professional quality paint job, either by waiting between coats or by baking. I've read that they go up to 400 something degrees at the factory, where paint shops will heat panels up to 150 or so.

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1314464255.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1314464255.2.jpg)

Wiring costs get pretty up there with this high amperage stuff. I needed to move my welder across the room. I ended up making my own 50 amp 20 ft extension chord and it cost me $250.

I broke down and got the runner kit for it which is ridiculous in its construction. The welder weighs 300 lbs and it's held to the rear wheel assembly only by 4 1/4-20 bolts into the sheet metal. The rear wheels look like 5 lug Fuchs though so it's worth it.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1314464255.3.jpg)

[nathansnathan]

The big bolts at the rear are a bear. Oh, 3/4" Bonney! (IMG:style_emoticons/default/bootyshake.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1315102885.1.jpg)

After much liquid wrench.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1315102885.2.jpg)

A giant release, a big pop and off she came. (IMG:style_emoticons/default/beer.gif)

[nathansnathan]

Some progress on the parts car. September 1st was the day I agreed to have it out of here. ... landlords and non-operational vehicles (IMG:style_emoticons/default/dry.gif)

Some guy talked my ear off All Day Long on Thursday, same guy that scavenged just the head off the old compressor that I put out with a free sign leaving me to deal with the rest. (IMG:style_emoticons/default/evilgrin.gif) I guess I was just nervous about how to proceed that I wasn't like, "I need to get to this, mister" and be on with it.

I'd got out my new sawzall.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1315106182.1.jpg)

I suppose I didn't really want to cut it up. I still wonder if I should have made a jig to store it vertically. (IMG:style_emoticons/default/screwy.gif) With all these parts, bring it back... (IMG:style_emoticons/default/chair.gif)

Pretty rusty in places.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1315106182.2.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1315106183.3.jpg)

And with the deadline, on went the plan to cut it up. Someone might need the metal; I'll keep it around, will need some myself: the cowl piece may be better than mine. Thinking about modifying the driver side engine mount back to be a passenger side?
Made a rack to make some room for the chopped up car.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1315106183.4.jpg)

Things went better on Friday without Mr. Diarrhea mouth, got a fender off after work.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1315106183.5.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1315106183.6.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1315106184.7.jpg)

Today, I got off the other front and the driver rear, will do the passenger rear tomorrow.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1315106184.8.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1315106184.9.jpg)

Came a long way in a week with it.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1315106184.10.jpg)

Looks like there was a fire under the dash at some point. Sure is crusty.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1315106185.11.jpg)

That's all for now. I'll finally be able to work on the blue car soon with this out of the way. It's actually almost not-blue as I've been taking off the paint, will show some of that later. Next step is ro get the blue car ready to transfer to the dolly, well after I get the rest of the donor cut and have made some room... (IMG:style_emoticons/default/smash.gif)

[nathansnathan]

Back a step to show there has actually been progress.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.smileyvault.com-11782-1317530913.1.gif)


It did get brutal when I removed the old suspension console, was more than a year ago.




(IMG:style_emoticons/default/welder.gif)


(IMG:style_emoticons/default/welder.gif) Bit of work to get both sides looking solid



bit lumpy, but passable. They don't sell this as a replacement piece afaik. 3M weld thru primer.






I've got some more plug welding to do; waiting on a big ass c-clamp to hold it together way in. A bit of a fit up of the outer suspension console.


The inside, fitting


I've cut out pieces of the long from the donor car to get the curvature without having to make tooling for the bender.


(IMG:style_emoticons/default/happy11.gif)


Got the driver engine mount off and seperated. This cleaned up nice (this is before (IMG:style_emoticons/default/smile.gif) ). I've got a paper template only, for the bottom part, the passenger-side version.


Working toward completing the inner long, those corrugations at the bottom, I can use parts of the driver-side long of the donor for the outer layer, I've got to make the inner, Richard Castro-style, as his thread is the only one I've seen really address the intricacies of the lower long.

Looked through like 3 times this many swatches. My neighbor down the way is an upholsterer and is going to help me get the interior in shape... once I get it painted.


I'm not sure if it's what I will go with as I'd like it to be more 70's 'camel', but out of all the ones he had this was the closest, it's sahara beige, a 996-7 color. This is leather, not leatherette which I think I might prefer, as he says that it will be mostly labor the cost. He's going to get me some more swatches, we'll see. I'm more concerned about camel-ish square-weave carpet.


I've sanded it a bit more, got the cowl and working on the gas tank compartment now. I ordered metal prep and primer, ppg, from the paint store. I'll need to get the long together before I can move the car onto the dolly in order to set up the ladder to move the lights and hang the divider. I can't wait to cover this metal up. I don't know how the anklebiter sits around like that. (IMG:style_emoticons/default/biggrin.gif)
(IMG:style_emoticons/default/poke.gif) That's the entirety of the donor car there in the corner.