Bringing out the dead Options

[Jeff Hail]

Projects, projects........always a monkey wrench thrown in for good measure somewhere.

One of the projects formula was I had to retain the stock rear calipers and use spacers for the wide Carrera rear rotors. (to retain the E-brake) Spacers easy. Fasteners not so easy. I could have used Grade 10 1/4x28 bolts but I did not feel the safety factor of 20% was there. I researched and contacted Verbus. They provided the specs for the original 914 caliper bolts and confirmed my research that Grade 10 did not provide the safety/ failure factor I required. Verbus also does not make a longer caliper half/bolt in 12.9 grade. No one makes an off the shelf bolt this length.

Guess what no one including Multi-Specialty-Metric fasteners had the M7 bolts that would survive hell and back with a 20% safety factor. I learned long ago do not sacrifice or compromise anything when it comes to brakes and hardware. First rule in racing is you can only go as fast as you can stop.

I called an old aquaintance to the challenge. Gary at ARP (Automotive Racing Products). Through the "specialty department" I worked with Jay in manufacturing custom M7 fasteners that would even exceed the 8mm bolts used on the 911 Carrera calipers. 190Ksi caliper bolts with 12 point heads. Unobtainium!

Cost was startling but I did not have much choice. Still a bargain when you compare to a ready set of 914/6 calipers.

These fasteners come into "unobtainium" category when you look at the tensile strength specs. Far exceeding the 20% safety factor and the extra 14 mm in width will not flex or break. Money well spent.

[Wes V]

Jeff;

Couldn't ARP have done it with studs and nuts with hardened washers. It sure would have been easier to manufacture.

Wes V

[Jeff Hail]

Jeff;

Couldn't ARP have done it with studs and nuts with hardened washers. It sure would have been easier to manufacture.

Wes V

The length was an issue as strength diminishes with length. 8mm was not an option as the calipers do not have enough meat to drill out. The strength is based on the diameter ,grip area and length of the fasteners. Longer bolts (through), washers and nuts were not recommended with the heat span calipers are subject to. Growth and contraction with heat affect dimensions. This possibly could result in the caliper halfs shifting ever so slightly which could result in fluid seepage between the halfs. Studs were considered but would have still had "play" because the outer half would still need to be drilled to 7mm.

12.9 and higher grade fasteners require a 90% proof rating. In plain english when you torque the fasteners properly a given amount of stretch occurs. Grade 12.9 bolts are tightened right up to their 90% proof load. There is no other effective way to tighten a grade 12.9 bolt. Grade 12.9 bolts do not work effectively with spring washers or shakeproof washers. These don't bite into the hardened surface of the bolt.

[Eric_Shea]

So... ARP makes the fasteners. Red Green supplied the spacers. (IMG:style_emoticons/default/biggrin.gif)

I just finished a set of Carera (IMG:style_emoticons/default/wink.gif) rear calipers with the "honk'n" spacers (not as sexy as your's mind you...) and the Verbus M7 hardware was (I think) 65 and 70mm. No workie? (IMG:style_emoticons/default/confused24.gif)

Damn (IMG:style_emoticons/default/headbang.gif) I just mailed them out this AM and I could have checked.

Fasteners look slick Mr.

[Jeff Hail]

So... ARP makes the fasteners. Red Green supplied the spacers. (IMG:style_emoticons/default/biggrin.gif)

I just finished a set of Carera (IMG:style_emoticons/default/wink.gif) rear calipers with the "honk'n" spacers (not as sexy as your's mind you...) and the Verbus M7 hardware was (I think) 65 and 70mm. No workie? (IMG:style_emoticons/default/confused24.gif)

Damn (IMG:style_emoticons/default/headbang.gif) I just mailed them out this AM and I could have checked.

Fasteners look slick Mr.

Funny thing is M7 hardware is found all over the world on cars, bikes everwhere. Just cant find replacements in these lengths in the aftermarket.

Your measurements are correct 65,70mm -why did they not work?. Bet they were 8's huh?

I thought the Carrera bolts were 8mm? Actually I think the early one's were 7mm.
Fronts were 8 for sure....maybe....ok I admit not sure on the early's. (IMG:style_emoticons/default/huh.gif) The lates pretty damn sure though. (IMG:style_emoticons/default/poke.gif)

Never dealt with Red. Wasn't he the guy from "The Taking of Pelum One Two Three" back in 1974? (IMG:style_emoticons/default/stirthepot.gif)

[Jeff Hail]

Haven't worked on the tub in a few weeks. Now I can get back to my regular programming.

Then today my friend Chris sends me this. Have a feeling I am going to get sidetracked helping out.

[Eric_Shea]

Your measurements are correct 65,70mm -why did they not work?. Bet they were 8's huh?

No, they worked fine for me. I was asking why they wouldn't have worked for you. It seems it would be less expensive to pick up a core pair of rear Carrera calipers and steal the fasteners.

I'm fairly certain all rear Carrera calipers are M7. The set I rebuilt had the 65 and 70mm M7... I really can't recall if they were Ribe or Verbus. The funny thing with M7 stuff on Porsche calipers is they are both Verbus and Ribe on the same caliper. Ribe made the longer fasteners on the 914 front caliper and Verbus made the shorter ones. Maybe this is why Verbus didn't have anything listed... (IMG:style_emoticons/default/confused24.gif)

Ribe is listed at 12.9 and Verbus is 11.9

[Jeff Hail]

Your measurements are correct 65,70mm -why did they not work?. Bet they were 8's huh?

No, they worked fine for me. I was asking why they wouldn't have worked for you. It seems it would be less expensive to pick up a core pair of rear Carrera calipers and steal the fasteners.

I'm fairly certain all rear Carrera calipers are M7. The set I rebuilt had the 65 and 70mm M7... I really can't recall if they were Ribe or Verbus. The funny thing with M7 stuff on Porsche calipers is they are both Verbus and Ribe on the same caliper. Ribe made the longer fasteners on the 914 front caliper and Verbus made the shorter ones. Maybe this is why Verbus didn't have anything listed... (IMG:style_emoticons/default/confused24.gif)

Ribe is listed at 12.9 and Verbus is 11.9

The original Verbus I pulled off was 12.9 on all. One concern was when they are proofed (torqued to 90%) they really arent supposed to be reused over and over. I doubt I would ever have a problem but don't want to find out.

[Jeff Hail]

Back to the regular program.........

Stripped the nose and primed today.

3rd pic shows driver side cowl with a bit of rust in the usual place.

[Jeff Hail]

Easy day

[KELTY360]

Haven't worked on the tub in a few weeks. Now I can get back to my regular programming.

Then today my friend Chris sends me this. Have a feeling I am going to get sidetracked helping out.

So when does the engine go back in the Mulholland RSR?

[plymouth37]

My god those fenders are fricken amazing! How much for a set, serously I need those, where should I send the check?
You are going into production with these whether you like it or not!

[Jeff Hail]

Haven't worked on the tub in a few weeks. Now I can get back to my regular programming.

Then today my friend Chris sends me this. Have a feeling I am going to get sidetracked helping out.

So when does the engine go back in the Mulholland RSR?

When my phone rings?

[Jeff Hail]

My god those fenders are fricken amazing! How much for a set, serously I need those, where should I send the check?
You are going into production with these whether you like it or not!

Lot of time to make them Dana. I did make 4, other 2 are in storage as spares- I hope I will never need them. Believe me I thought about making a run but they were very time intensive to do. The last two I pulled in a big hurry and distroyed both molds in the process. No kidding.

I will be doing a set of 12 inch rear flares in c/f soon. These will be tricky as I have no plug to pull a mold from. I have a few ideas though (IMG:style_emoticons/default/happy11.gif)....running around this head of mine.

By the way nice project you are doing. You have impressive skills.

[Jeff Hail]

Fitting the front structure. Just tacked so I can square all the pieces during the mockup.

Fit of the pieces is perfect considering it began as an email and photo in California and fabbed in Conneticuit (by Chris Foley). Chris's work is first rate.

All ties into the lower control arm and suspension crossmember control points at the same time triangulating the nose and cowl. Very light weight.

Hey Chris think the headlight motors are going to fit?

[Eric_Shea]

Looking great Jeff. Is a GT shroud going to fit in there? Are those bottom pieces going to tie into the crossbar somehow?

I've been wanting to do the same bracing up front but I haven't been able to figure out a way around the oil lines on the left and the fuel pump on the right. Looks like your design would clear the fuel pump though.

[Jeff Hail]

Looking great Jeff. Is a GT shroud going to fit in there? Are those bottom pieces going to tie into the crossbar somehow?

I've been wanting to do the same bracing up front but I haven't been able to figure out a way around the oil lines on the left and the fuel pump on the right. Looks like your design would clear the fuel pump though.

The lower base plates at the bulkhead attach directly on the opposite side of the suspension crossmember mounts. Those will get reinforced also inside the tunnel spreading the load area out further.

Gt shroud? Nope! Have something else in mind.

[Jeff Hail]

Have not had much time to play. Day job busy. Helping others with projects. Like they say nice guys finish last!

The passenger side of the car is officially completed (minus RR flare which is will be done soon in CF).

Today I finished all the mounts for the right side front fender. Added the two remaining Dzus fasteners on top. Little things take time. Done!

All the mount brackets on the underside also have backing plates bonded to the fender itself so it does not crush or crack.

[Jeff Hail]

Finished up the front structure.

It is still only tacked at the base plates but all the tube to tube joints are welded.
I need to cut the tacks and work on the right side front control arm mount bracket. (it has a minor issue to address)

[ChrisFoley]

Looks good Jeff!

Eric, a gt cooler shroud would fit fine. The tubular structure is wider and higher than the f/g piece.