Bringing out the dead Options

[Jeff Hail]

HOW TO BUILD A CLUTCH TUBE -Cont'd

Last picture is the cable (engine side) in the opposite end of the tube. Cable and liner travel freely. Once installed in the car I will size the rear end of the tube to 32-34mm protrusion at the lower firewall.

Whole process took about twenty minutes.

[Jeff Hail]

Holidays, birthdays, anniversaries, end of the year, and business are not conducive to project progress. They each have a place though. Throw in a little 10 day vacation for myself and back to work.

Split the tunnel open at the shifter to get the old conduits out. Good bye to that rusty rat's nest of tubes out. The original throttle cable conduit was rusted and broken midway at the support. This was like dental work as the confines were tight and I really didn’t want to butterfly the entire tunnel open.

Time and patience make the end result worthwhile.

First photo shows the cut. The shifter opening is reinforced. It is doubled layered and has the three nutplates wekled on the underside. First peel the tunnel back and then cut the right front of the reinforcement out.

Second photo all the old conduits are out.

Third photo........by the way the site just burped and I had to re-post again.
Third photo I have welded the shifter reinforcement back in. After grinding I couldnt even find the seam.

[Jeff Hail]

Inside the tunnel running on the left side is a shield that the throttle cable conduit runs through along side the shifter. To remove the old conduit I had to drill the spot welds only at the bottom to get the tube out. It is brazed at the rear and a twist of the tube with pliers breaks the braze with ease.

First and second photo shows the red punches and vise grips holding the shield in alignment for welding. I stuck a piece of tubing in the cavity to make sure I have enough clearance to fit the throttle cable conduit later.

Third photo shows the fabbed conduits sticking out the back of the tunnel. These will get cut to fit once the lower firewall is in place.

Last photo shows the throttle and clutch cable conduits at the front of the tunnel properly spaced. Always take measurements before you swap something as critical as these. The tunnel and conduits do not give second chances once everything is sealed up.

Now that everything is fit I will fab a couple more brackets to locate and secure the conduits permanently inside the tunnel.

[Jeff Hail]

Since I havent been getting a lot done on the tub lately I might as well post something of interest. Consider it like "Intermission at the Drive In Movie" without the popcorn.

Porsche Factory Tools, Gauges, Chassis Fixtures.
Since most of these tools are NLA and long gone unless used for other models like the 911 most people have never seen. Some of the manuals have poor pictures of them but most of what you see here will be the first time.

Enjoy!

Starting off with the simple ones:
1) Rear hinge tool

2) Wheel bearing installation tool (love the mallet)

3) Shifter bushing driver (metal dowel)

3-4) Strut alignment gauge

[Jeff Hail]

5-6) Rear caliper vent clearance gauge (Erics going to make one of these)

[Jeff Hail]

And the more complex tools and fixtures for the chassis.

I actually saw this set back in 1981. The front suspension fixture is also used 911's. Today it it considered priceless. To think some shop owners in the 1990's probably ended up throwing them out of scrapping them because they were old and insurance companies were totalling all the late 60's and 70's Porsches because the market was soft. Ugghhhhhhh!!!!

[Jeff Hail]

Contd

[Jeff Hail]

Technical documentation:

Porsche new early on the 914 was prone to rust.
1) Dealer Bulletin on Corrosion


2) Detailed schematic of where foam, sealant and undercoating locations were along with grommets and hole plugs.
This document is scary! Every where there is foam we now have rust!

[Twystd1]

Jeff,

I am dam glad you posted. As I was considering creating a new post with the byline of "WHERE THE HELL IS HAIL...?????"

And here ya are... !!!! Ya must of heard me.

Jeff, Can ya PM me your phone number? I might be coming up your way next weekend. And hoped I might drop by again and check in with you.
You supply the coffee. I supply the smokes.

You should be shooting video of this build.

Think about it for minute Jeff. We could sell a "HOW TO RE-BUILD A 914 BODY VIDEO" And sell it hand in hand with my soon to be famous and forthcoming, "HOW NOT TO BUILD A TYPE IV ENGINE".

Dude... We could be in the bucks real quick me thinks. I still have to get my video cam repaired, as I was trying to fix the power supply section of my camera. And apparently I did something a bit wrong.

(I thought they plugged into the wall socket... But no.. It takes battery's. Who woulda thunk...????????) (Must be a Chinese thing)

Bottom line.. Good to have ya back.

Cheers,

Clayton

[Jeff Hail]

Jeff,

I am dam glad you posted. As I was considering creating a new post with the byline of "WHERE THE HELL IS HAIL...?????"

And here ya are... !!!! Ya must of heard me.

Jeff, Can ya PM me your phone number? I might be coming up your way next weekend. And hoped I might drop by again and check in with you.
You supply the coffee. I supply the smokes.

You should be shooting video of this build.

Think about it for minute Jeff. We could sell a "HOW TO RE-BUILD A 914 BODY VIDEO" And sell it hand in hand with my soon to be famous and forthcoming, "HOW NOT TO BUILD A TYPE IV ENGINE".

Dude... We could be in the bucks real quick me thinks. I still have to get my video cam repaired, as I was trying to fix the power supply section of my camera. And apparently I did something a bit wrong.

(I thought they plugged into the wall socket... But no.. It takes battery's. Who woulda thunk...????????) (Must be a Chinese thing)

Bottom line.. Good to have ya back.

Cheers,

Clayton

Clayton! Whats up dude?

Yeah been kind of quiet on the tub lately. Busy at the day job. Damn cold up in these hills. At least for this California boy. 30-40 degree's is too cold for me. I would never make it on the east coast unless I had a heated garage. Today it crept up to a high of 60 and me with an empty cylinder of C02/Argon. I have been picking up a bunch of parts for the build and getting other things done. Foley has my suspension pickups done. Should be here Tuesday or so. All is not idle. Little things have to get done too. When its done its done. No hurry.

Video of the 914 chassis reconstruction? It would be up there with the greatest story ever told. At least as long! And I have the perfect title! "IT'S ONLY MONEY".

Pm sent

[Jeff Hail]

This is what I am going with for shifting the 915. PMS supplied and they also built the trans mount hoop. Lighweight and stout.

[Jeff Hail]

The Fedex and UPS guys are beggining to get suspicious. Many large boxes arrived yesterday all at once.

Suspension pickups from Mr. Foley and the Rota's came in.

These are the Rota Fox (Fuchs Repros) in 7-1/2 x 17 and 9x 17. I ordered them unfinished (comes in primer). I will have them powdercoated in mat black on the entire wheel. No shiney stuff on this build!

It's only metal and money. You can't take it with you.

[tdgray]

Ooooohhh Pretty (IMG:style_emoticons/default/wub.gif)

[Jeff Hail]

Kept the Powder Coat and Blaster guy busy for a couple of hours.

Old grungy pedal assembly

and the new and improved model

Why silver? The coater was doing a large job and did it for free. Once they are under the pedal board you won't see much. (RAL Anodized Silver)

[Jeff Hail]

Naked trailing arms

[Jeff Hail]

A full day to play.

Installed both the new throttle and clutch cable conduits in the tunnel.
The repros I made were pretty accurate. The angle of attack on the front flared ends was perfect.

Welding inside the tunnel is difficult at the same time tense. After all the tacks you just hope you don't burn a hole thru the tubing and end up having to start over.
I didn't get a chance to test fit the cables yet but I think I did not perforate any of the new tubes.

At the front mouth of the clutch tube I welded a sleeve over the tube prior to install. Since the clutch tube has some decent presure on it during usage it needs to be more stout than the throttle cable tube. The sleeve let me get some heat into the remnant of the old bracket still in the tunnel without burning a hole in the tube itself.

Threw some rattle can primer on for now. Still need to grind the welds on the outside of the tunnel to clean it up.

Looks like some rain coming.

[Jeff Hail]

Busy few weeks at work. Rain, rain and more rain coming tomorrow.
No time to play..............

Garage time

Boxed the rear trailing arms today.

[Jeff Hail]

They look really ugly will all those plug welds.

After grinding all the welds........one down......
I will grind the other one in the morning and send them off to the powdercoater

[Jeff Hail]

Completed all the finish grinding today on the trailing arms.
Threw on some primer til they go to the powdercoater.
Came out slick

[Jeff Hail]

Got a lot done this past week.

Stopped in to say hello to Peter at Rennspeed. http://www.rennspd.com/
Ended up leaving with a perfect set of GT Rocker moldings and an Oil presure/ temp gauge I have been hunting. The rocker moldings are perfect side to side length. This seems to be a problem with other suppliers. The flared ends also match the steel flares contour perfect.
Never ever stop in to say hello when you have a wallet full of cash at any Porsche parts establishment.

Sent the transaxle out to flip the R&P on the 915. I added a few modifications "since there in there". A hardened steel bearing carrier. All new syncro rings. G50 speedometer Hall sensor for inverted R&P. How much? Do not ask!

And the week culminated with beautiful weather here in SoCal. One full day to work on the car and finish some things up.

I hated to cut the quarter panel but no way to access the inner wheelhouse replacement. It will end up cleaner in the end. Managed to save the pillar in the process. Reminds me of Milchelko's "diggi'n into hell".