75 S to R Homage

sladey · Post by **sladey** » Thu Mar 03, 2011 9:48 am

You see that dot in the distance - that's my knowledge receding over the horizon behind you as you gallop forwards.

Impressive stuff!

haasad · Post by **haasad** » Tue Apr 05, 2011 8:06 pm

A bit more progress to report.

Piston squirters bloked solid removal underway.

And some simple interior work

and just because I'd forgotten it comes out of the garage sometimes

really must take some of it in its new livery too

thanks for looking

Mike911scrs · Post by **Mike911scrs** » Thu Apr 07, 2011 6:42 pm

HI Andy
what pressure where you using to check the opening of the piston squirter's????

regards mike

haasad · Post by **haasad** » Thu Apr 07, 2011 9:18 pm

hi mike i tried up to 100 psig they were corroded solid .I think its my fault after chemically cleaning the cases and not flushing properly a few years ago ! its probably best to replace anyway.

i was a bit shocked by the price of new squirters !!! but i figure i save enough by diy to take the odd hit

andy

sladey · Post by **sladey** » Thu Apr 07, 2011 10:40 pm

Hi Andy,

Can I ask how you cut the cooling slots in the front bumper and kept them even etc?

haasad · Post by **haasad** » Fri Apr 08, 2011 8:55 am

Hi, it was simple. I covered the area in white fablon. Carefully marked out the slots with a 6 inch steel rule and a fine permanent marker. The radius at the end was drawn around a pound coin I seem to remember. I marked a straight line at the top and a parallel one at the botom for a length reference. The bumper was on the car so I could mark it all out parrelell to the ground as far as possible.

Then I simply cut by hand inside the lines with a fine hacksaw blade to remove the bulk. I filed the straight edges to the line and used a high speed rotary tungsten burr to get the radii nearly right before finishing by hand with a combination of a file and 400 wet and dry wrapped around a piece off steel stock bar to keep the radius constant.

2 hours max I reckon. I copied it from a KREMER car photo I found.

sladey · Post by **sladey** » Fri Apr 08, 2011 9:02 am

Brilliant - thanks for that Andy

haasad · Post by **haasad** » Wed Apr 27, 2011 5:53 pm

bit of time off and some progress. I needed to raise the spindles on my KONI struts ( yes I know they're green) to give some clearance for my big discs on the bottom ball joint. I had already made new spacers to push the disc out as far as the spindle would allow but it still rubbed badly.

I sorted out how and a friend with a die grinder helped out. Its basically simple I moved the spindle 17mm up the shock diameter. I reckon 20 to 25 mm is the max but the wheel would hit the ball joint about then so not a lot of use going that far.

Its ready to re-weld tommorow i'll weld it around the spindle forging diameter just to be sure , I think I'll also bend the steering arms to cut out the bump steer.

Watch this space for rebuild details on the original adjustable KONI internals.

I also carpeted the tunnel and wrinkle finished the back cover ready to fit.

and plumbed the fuel pumps and tank vent.

Hope to finish the carpet gluing tommorrow ready to order the bespoke mats for the floors and rear seat buckets.

Back to a beer in the garden now ( oh and watch out for some details of a twin plug dizzy too

)

andy

911hillclimber · Post by **911hillclimber** » Wed Apr 27, 2011 6:14 pm

Good to see more DIY action!
What welding wire will you use for the cast steel/ 'drawn tube?

Graham.

haasad · Post by **haasad** » Wed May 04, 2011 7:57 pm

Spindles raised 17 mm so discs will clear and the ball joint won't hit the rim. I reckon you can get 20 mm easily on these struts , debating wether to bend the arms to correct bump steer ( but I've primed them now

)

Original Koni open bath adjustable dampers stripped. All valves relapped . All reassembled. Oil is 15 weight fork oil.I also now know how to refill and refit .

At least they'll be close to the right colour when they go back

The rosette weld was re-made and the spindle forging also welded to the tube while I was there. Normal eutectic rods.

Thanks

andy

sladey · Post by **sladey** » Thu May 05, 2011 9:12 am

Impressive work as usual.

Looking at this picture carefully, 3.99 seems a lot to pay for fork oil - round our way we'd probably pay fork oil for fork oil.

Sorry, I couldn't stop myself. I'll get me coat...

haasad · Post by **haasad** » Mon May 30, 2011 3:48 pm

Strut install completed (including bumpsteer corrected arms) The discs now clear the ball joints

The struts take 350 cc of fork oil and now work beautifully.

Brakes bled no leaks and a lovely solid pedal. Its so nice making bits work that haven't ever done so or haven't for at least 15 years.

andy

911hillclimber · Post by **911hillclimber** » Mon May 30, 2011 5:41 pm

Good going Andy!

Are those Boxter front calipers?

haasad · Post by **haasad** » Mon May 30, 2011 6:38 pm

They are 944 turbo calipers ( set of 4 ) I got them for free so why not

haasad · Post by **haasad** » Tue Aug 30, 2011 7:03 pm

Well with the exception of seat trimming the interior is finished. It's my interpretation of a lightweight set. Great Products and Service and Prices from Mega Van Mats and they cut and edged the mats to my patterns too.

And

Another day at the office....

I really should get out more..good job I'm on my holiday from real work...
One day I'll post some snaps of the motor which is very slowly coming together. My wife pointed out this has been a 9 year project so far.