Safari 914 project, “Sufari” Options

[East coaster]

A small diversion project to allow me to work in the heated portion of my shop on a cold damp day. Fab’d up the bracket for the clutch master cylinder.

[East coaster]

Machined a conversion part for the clutch clevis. Just turned a piece of 1/2” steel to make the clevis end the diameter of the stock clevis threaded area so the pin will still clip on, then a radius to the larger diameter to provide enough beef for the 8mm thread of the Honda master cylinder. Welded the new part to the stock clevis and all lines up and functions well.

[East coaster]

With radiator mount completed, it was on to the fabrication of the exit plenum. A little foam and filler to create a “buck”, then on to a little carbon/Kevlar layup. It came out well and I’m now laying up an entrance plenum to go between radiator and inlet opening. The plenums will have a thick rubber seal to isolate the plenum from the radiator and keep a tight seal.

[East coaster]

[East coaster]

Purdy……

[Montreal914]

I am still in admiration with your fiberglass duct work on your silver six (avatar), but now, even more! (IMG:style_emoticons/default/pray.gif)

A few questions:

What type of foam is this?
What type of adhesive are you using to bond the foam pieces?
What type of filler are you using?
Are you putting any protective layer on the filler prior to laying the CF over?
Are you using polyester resin with CF as you would for fiberglass?
Would all of this buck preparation process be the same for fiberglass?

I think this is such cool fabrication work! (IMG:style_emoticons/default/beer.gif)

Sorry for all the question... (IMG:style_emoticons/default/rolleyes.gif) (IMG:style_emoticons/default/beerchug.gif)

[Blue6]

I am still in admiration with your fiberglass duct work on your silver six (avatar), but now, even more! (IMG:style_emoticons/default/pray.gif)

A few questions:

What type of foam is this?
What type of adhesive are you using to bond the foam pieces?
What type of filler are you using?
Are you putting any protective layer on the filler prior to laying the CF over?
Are you using polyester resin with CF as you would for fiberglass?
Would all of this buck preparation process be the same for fiberglass?

I think this is such cool fabrication work! (IMG:style_emoticons/default/beer.gif)

Sorry for all the question... (IMG:style_emoticons/default/rolleyes.gif) (IMG:style_emoticons/default/beerchug.gif)

What he said….

[East coaster]

I am still in admiration with your fiberglass duct work on your silver six (avatar), but now, even more! (IMG:style_emoticons/default/pray.gif)

A few questions:

What type of foam is this? (Just some foam board from Home Depot)
What type of adhesive are you using to bond the foam pieces? (Hot glue gun)
What type of filler are you using? (A coating of joint compound, then a little bondo where needed)
Are you putting any protective layer on the filler prior to laying the CF over? ( I usually do but didn’t here. The foam breaks out of the finished piece and it leaves a layer of joint compound which sands off very easily)
Are you using polyester resin with CF as you would for fiberglass? ( I used West System epoxy)
Would all of this buck preparation process be the same for fiberglass? (Same for glass. In fact, this has a single layer of fiberglass mat under the carbon. If you use polyester resin you would need to use different foam, as poly will eat this type of foam)

I think this is such cool fabrication work! (IMG:style_emoticons/default/beer.gif)

Sorry for all the question... (IMG:style_emoticons/default/rolleyes.gif) (IMG:style_emoticons/default/beerchug.gif)

[slowrodent]

Super metal fab work.. And that plenum is wondrous. I love that solution. And your choice of footwear... the list goes on and on.. (IMG:style_emoticons/default/smile.gif)

[Retroracer]

Another nod to the excellent footwear - but adding to the composite questions:

- who do use as a supplier for the carbon/kevlar?
- are you using dye in the gel coat to give it that red coloring?

Great thread BTW!

- Tony

[East coaster]

Another nod to the excellent footwear - but adding to the composite questions:

- who do use as a supplier for the carbon/kevlar?
- are you using dye in the gel coat to give it that red coloring?

Great thread BTW!

- Tony

I got the carbon Kevlar material from US Composites. The red is actually orange Kevlar woven with the black carbon. It was a left over from one of my jetski projects.

[East coaster]

Finished up the entrance plenum. Final fitting/trimming will be held for final install, but it fits up pretty damn close now (leaving a little room for sealing). Now on to figuring out my cooling lines.

I added a piece of 1/4” chromoly tubing to the top of the radiator opening to stiffen things up a bit. It was pretty flexy at the top once the hole was cut.

[East coaster]

Surfing through a sea of wires………I plan to use the entire wiring harness from my donor Subaru. I’ve been paring it down to what’s needed in the 914. The large pile of wires is what’s been removed so far.

[East coaster]

I tore down my donor Suby engine and replaced head gaskets, oil pump, water pump, and timing belt. I also installed an aluminum oil pan for additional clearance. I’ll be working on flipping my intake manifold shortly.

[East coaster]

While the engine was upside down, I started fabricating the engine mount/cradle. Here’s the cross bar and motor mount plates coming together. I left the cross bar a little long until final fitting in the longitudinal cradle bars.

[East coaster]

Couple more pics….

[East coaster]

Got more done on the cradle today. Bent some 1-1/2” DOM for the longitudinal section and fabricated mount plates for the motor mount and trans mount body points. Got the longitudinals welded up and got the engine mount cross bar tacked for finish welding tomorrow. Next will be figuring out my trans mount to cradle interface.

[East coaster]

Fabricated the trans support and incorporated the mount into the cradle…..I’m callin’ the cradle done! (Well, except for some paint) Now on to the next challenge……

[East coaster]

Took advantage of some unseasonable February weather and got a jump on the body work. It’s shaping up nicely after the metal work.

[East coaster]

My focus on my project has been all over the map, mostly driven by our crazy Northeast weather. Today was an inside shop day and I started working my intake manifold flip. I stripped my intake and glass beaded the intake to clean it up. The flip is mechanically pretty straight forward, need just an 8mm spacer to raise the manifold enough to provide clearance for the fuel hard lines. The harder part will be re-wiring the harness a bit to account for the movement of the sensors, but even that shouldn’t be too difficult.