21st Century Outlaw 997 Project
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Re: 21st Century Outlaw 997 Project
Whew!
Mammoth work with mammoth results Darren.
Unique and must be very satisfying to see it all finally.
Mammoth work with mammoth results Darren.
Unique and must be very satisfying to see it all finally.
73T 911 Coupe, road/hillclimber 3.2L
Lola t 492 / 3.2 hillclimb racer
Boxster 987 Gen II 2.9
Lola t 492 / 3.2 hillclimb racer
Boxster 987 Gen II 2.9
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Re: 21st Century Outlaw 997 Project
Like that
1972 911T | 1994 993 Carrera | 1999 986 Boxster | 1990 T25 Camper
Vintage Heuer, Omega, Zenith and other vintage watches - http://www.heuerheritage.co.uk
Vintage Heuer, Omega, Zenith and other vintage watches - http://www.heuerheritage.co.uk
Re: 21st Century Outlaw 997 Project
Stunning!!
Porsche 964 1993
Porsche 944 1986 - sold
Porsche 914 1972
Porsche 944 1986 - sold
Porsche 914 1972
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Re: 21st Century Outlaw 997 Project
Lovely finish and so much attention to detail .
1971 Targa Sportomatic in Green 1972 2.4e sunroof coupe 1990 964 C2 Member no 82
Re: 21st Century Outlaw 997 Project
Thanks for the kind comments
So to continue, I started to make up my own rear exhaust section to join onto the Eurocup Full Flow Stainless system installed during engine rebuild. Starting with the link plate made previously & some pipe fittings
Next I got hold of some 108mm diameter stainless pipe to make the tailpipes, cut to length and squared off the ends precariously in the lathe
So to continue, I started to make up my own rear exhaust section to join onto the Eurocup Full Flow Stainless system installed during engine rebuild. Starting with the link plate made previously & some pipe fittings
Next I got hold of some 108mm diameter stainless pipe to make the tailpipes, cut to length and squared off the ends precariously in the lathe
@classiccarguru1
Re: 21st Century Outlaw 997 Project
Next I marked out the relief so that it could sit flush in the link bracket
Then cut them out
So it all fit snug
Then cut them out
So it all fit snug
@classiccarguru1
Re: 21st Century Outlaw 997 Project
The tip rims were then set up, paying attention to the position of the split rim holes (so the petal centres would be vertical & matching) and marked out for condensate drain semi circular holes. In this way the tips wouldn't collect water on start up.
Repeat for both
Then carefully machine out a relief in the rear of the "rim" to match the 108mm tube
Repeat for both
Then carefully machine out a relief in the rear of the "rim" to match the 108mm tube
@classiccarguru1
Re: 21st Century Outlaw 997 Project
The rims were the micro tig welded to the tube from the inside. A bit like wallpapering your hall through the letterbox
Then after a polish to remove blueing the centres were fitted using the M1.6mm nuts & bolts. Fiddly a fook, ended up using a sticky caulking to hold the nuts as they're too small to pick up by hand
Then after a polish to remove blueing the centres were fitted using the M1.6mm nuts & bolts. Fiddly a fook, ended up using a sticky caulking to hold the nuts as they're too small to pick up by hand
@classiccarguru1
Re: 21st Century Outlaw 997 Project
Every M1.6 nut & bolt was fitted with locktite & tightened with a homemade spanner.
Then just when my eyes & patience had gone complete, I had the second one to do
Then just when my eyes & patience had gone complete, I had the second one to do
@classiccarguru1
Re: 21st Century Outlaw 997 Project
Out with the welder again, set up pipe & fittings, then tack in place.
Once this was tacked up I found that the two rear lower 997 bumper supports fouled the new pipe & wouldn't let it sit far enough to the rear to clear the CATs'
So make two new ones
To be fair the old ones were a bit scabby, so I used some 6mm stainless for the new brackets, shaped concave (as opposed to the original convex, to follow the contour, just behind the bumper for maximum space.
Once this was tacked up I found that the two rear lower 997 bumper supports fouled the new pipe & wouldn't let it sit far enough to the rear to clear the CATs'
So make two new ones
To be fair the old ones were a bit scabby, so I used some 6mm stainless for the new brackets, shaped concave (as opposed to the original convex, to follow the contour, just behind the bumper for maximum space.
@classiccarguru1
Re: 21st Century Outlaw 997 Project
The big day arrived when it was time to do a dry run on the car, which involved cutting back the Eurocup pipes just before the original 997 tips.
So with brave pills at hand I cut them with an angle grinder, then tube cutter on my new assembly to suit.
Measure 26 times, cut once
The bumper brackets were swapped over, then with the aid of a pair of swaged 90 stainless bends, chocks & lots of measuring, I tacked it in position.
So with brave pills at hand I cut them with an angle grinder, then tube cutter on my new assembly to suit.
Measure 26 times, cut once
The bumper brackets were swapped over, then with the aid of a pair of swaged 90 stainless bends, chocks & lots of measuring, I tacked it in position.
@classiccarguru1
Re: 21st Century Outlaw 997 Project
The whole assembly was then removed for fully welding up.
With its proximity close to the inside of the rear valance & CATs I decided to heat wrap it in these positions after welding.
Being a paranoid engineer, I thought it prudent to make a spring hanger to support the section by the tailpipes. Not that they're heavy, more peace of mind, as there's an additional overhang weight that wasn't there before.
Just by chance the 997 has heat shield threaded fixings dead centre above where I wanted to put the hanger, so these were used in combination with some extra ones.
With its proximity close to the inside of the rear valance & CATs I decided to heat wrap it in these positions after welding.
Being a paranoid engineer, I thought it prudent to make a spring hanger to support the section by the tailpipes. Not that they're heavy, more peace of mind, as there's an additional overhang weight that wasn't there before.
Just by chance the 997 has heat shield threaded fixings dead centre above where I wanted to put the hanger, so these were used in combination with some extra ones.
@classiccarguru1
Re: 21st Century Outlaw 997 Project
All that was left to do was make up a bracket on my exhaust to join with the spring hanger. Using a "spare" link & tubes I'd made if it all went Pete Tong, I took some more measurements.
Then imagineered a bracket in Stainless
And welded it in place
Then imagineered a bracket in Stainless
And welded it in place
@classiccarguru1
Re: 21st Century Outlaw 997 Project
Finally the assembly was Polished to remove all weld blueing & refitted back on the car with some new pipe clamps, and the spring hanger tension set
The last job was then to swap out the 991 lower valance insert that I'd cut for the original wide spaced 997 tailpipes, with a new one. This is in two parts with a separate insert around the centre tailpipes. I decided in the end to cut about 2" off the bottom to reveal the 21st Century Outlaw script for all to see
The last job was then to swap out the 991 lower valance insert that I'd cut for the original wide spaced 997 tailpipes, with a new one. This is in two parts with a separate insert around the centre tailpipes. I decided in the end to cut about 2" off the bottom to reveal the 21st Century Outlaw script for all to see
Last edited by Darren C on Mon Sep 17, 2018 11:27 am, edited 1 time in total.
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