Bringing out the dead Options

[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".

[Jeff Hail]

No rust left here. All new steel.

Made another fixture to keep the longs in check. Threaded rod with plates on each end. Tack welded to the inner longs. Keeps the dimensions in check and the longs won't splay in process.

Remember to take measurements before you begin cutting off stuff. Especially the suspension consoles

[Jeff Hail]

More on measuring.

Do not proceed without measuring before you cut. This is vital to returning a chassis to dimensional tolerance. You do not have to high tech equipment. A tape measure will get by if on a budget. Pre- measure both sides before you cut any suspension consoles off.

[Jeff Hail]

Finished the long connection at the rear rail. Added a sleeve at the joint. This will strengthen the connection and eliminate the flex at this area that 914's at notorious for.

Notice I punched holes in the sleeve. Since this is a area known for corrosion I did the work from inside the long. No leaks from pin holes in any welds will happen here. Also less finish work required since it is all inside once the long is closed up.
Work smart -not hard!

[Jeff Hail]

Twice as strong as the factory design in this area. No welds from the outside except the outside butt joint equals no water leaks in this area.

I rough fit the new outer wheelhouse ( oops didn't take a pic)
I little more trimming needed but should be installed next weekend.

I am actually considering modifying a shelf where the rear diagonal long meets
the inner long at the firewall. An angled addition of sheetmetal to make water run off and down away from the long. Easy to do and hardly noticeable. More on that later.

[Jeff Hail]

Value in scribbled notes:
I am sure this will help someone one day!
Measurements...........

Seat hinge mounting

[Jeff Hail]

More value in scribbled notes:
I am sure this will help someone one day!
Measurements...........

Outer suspension console specs...............

[Jeff Hail]

More value in scribbled notes:

Measurements...........

Inner suspension console specs...............

[Jeff Hail]

More scribbled notes:

Measurements...........

Jack post tube............... if you want your rocker moldings to fit correctly (tube centered in the rocker molding cutout hole)

[type11969]

Looks familiar . . . just much nicer!

-Chris

[Eric_Shea]

How long before my "Rock Crusher" is done... (IMG:style_emoticons/default/confused24.gif)

http://www.914world.com/bbs2/index.php?showtopic=80797

[Jeff Hail]

Two weeks! Isn't that what all shops say?

[Twystd1]

Eric, I have seen Jeff's work first hand.

Your rock crusher should be done in 9 days if I read it right.

C

[Jeff Hail]

Might as well add this to the thread (IMG:style_emoticons/default/welder.gif) too:

The design make's everything a one man operation. The width of the upper bed is 32 inches wide which fits between the rear inner console ears that are the lowest part of the car. The height from the ground up was based on the maximum height of the common floor jack +2 inches (adding 2x2x 6 foot) cross bars that sat on jackstands and the bench rolled right underneath with a hair to spare? Of course easy access to gain access and roll around underneath on a creeper was taken into account.

[Twystd1]

This is my favorite thread on this site so far. I LOVE THIS STUFF.

Clayton

[Zimms]

(IMG:style_emoticons/default/agree.gif) Thanks for posting all of the sketches. I am going to be starting something similar this summer.

[Jeff Hail]

Lets make some Sill Triangles

Made 2 templates. The first one is actual size after the bends (silhouette) of the mounted original. The second is 3/8 larger all the way around.

Cut out the sheetmetal using the larger template and then trace the smaller (silhouette) template onto the cutouts. Then drill the holes. I am making right and left sides.

Make some relief cuts so the bends don't buckle the flat area's. I tacked some really small welds where the sill plate doglegs over the bracket for strength.

These were the tools used in the process and a metal scroll saw to make the cutouts .

Finished triangle next to the original.