Project Blue Book

[sladey]

Yep great work as always - many thanks for sharing

[chief]

Managed to get a bit of time in the garage. I thought I would try to finish up the washer system and last bit of the brown paper/ foil tubing.

The original sytem hooked up the the spare tyre to get pressure to spit the water at the windscreen. So that wouldn't do. I managed to get a proper Porsche pump as fitted to just about all their models back in the day. I needed to get a nice factory looking spot to fit the pump. Not easy as the space is a little restricted under there. I fitted the paper hose to see what space was left. I fitted the cleaned washer bottle and lined up the pump to mirror.



The thought of self tappers made me shudder, so out with the rivnutter!









As the system is pressurised by the tyre I needed to add a one way breather so as to not stall the pump when operated.



This is off a BMW and is just one of there generic breathers for pipework. Just a case of drilling a hole in the top the pushing through. The end is the same as shown so I just pushed a short bit of washer tube to keep it in situ. I just need some more pipe to finish off the top.


New project, which is quite refreshing. I have what some would call VINTAGE! audio gear from 1986/7. I have never installed a complete audio set up before, so am really interested in this next project. I have a huge list of stuff arriving to complete this. So more later. Should be fun....









Do any of your remember when we used to have these carriage head units that pulled out and came with us????

Well Happy New Year all and I hope it's a healthy and peaceful one.

[rhd racer]

Cool development! Remember those well - not so convenient for going to the pub / walking round the shops!!


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[chief]

Thank you evero much fellas. I really appreciate the comments!

I have been busy in the garage with lots of things going on at the same time. But to get up to date, let's carry on with the Stereo install. I have to say it's a work in progress and by no means finished. There has been a lot to learn.



A lot of measuring with this one. Measure twice and cut once!

The firewall was the obvious place to put everything as there isn't much room in the cabin. The firewall isn't even all the way down so I have had to machine some threaded stand off's to get the mounting plate parallel.





The next image show how I am going to conceal the amp and crossovers.







You just press the centre of the button and they pop off.





So I went back to my woodworking routes and started to put together the cover. This will be trimmed after.



Lots of drilling and tapping threads to fit everything.







Taking shape. Lots of cabling to bring through from the cabin. I used a clean line from the battery to the fuseboard. This should cut down on interference noise.

The realys are for spot lights and a spare for anything else I want to install.

The eagle eyed of you will see that I did not use my old amplifier. I wnr for a new one with pre outs to fit a driven base box to go in the passenger foot well.

Just seemed an easier option.



Shown here are the relay for spot lights plus a spare and a set of 'Switched Lives' if needed along with tsome earths.

So with the main infrastucture sorted I could get back to fitting the petrol tank. I will revisit the stereo once i'm a bit further on with other stuff.

I will sign off now....

[rhd racer]

Looks cool

The amp will generate a lot of heat in a closed box though won’t it? Might hit the thermal cut off and cut out on you, and you know that will always happen when you are in the middle of LFO…..


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[chief]

Very good point. I’m hoping that the aluminium plate being 6mm with quite a bit of air gap behind will suffice.
Thank you for the ‘Heads up’ though. I’ll keep it in mind.

[chief]

Morning All.

Easter gave some time to shuffle along with the Project Blue Book build. All about the details now.

First off Angus, Sam and the chaps at 'Greatworth Classics' have been moving at some considerable pace with the build.







Some lovely 'Amberglas' on show. This was molded from my fiberglass engine shroud. I have spent a long time getting this to fit as it allows the original oil cooler to remain. These are quite a rare find!








Starting to take shape now.


Whilst they are busy in Banbury i'm playing catch up a home.

We left last time with my bumper project. So here is where we are at....

















SPOT LIGHT brackets were a right pain to make as the body shell is kinda boat pointy at the front so the brackets needed to be made at an angle to come through the bumper straight. This also meant threading them to be able to pop long cap head set screws loosely through to get through the bumper holes and then be tightend up at the same time as the bumper. This was because I only wanted the bumper holes to be a couple of 'mm' bigger than the bracket to keep it looking tight.


Here is one of the many trial fits and mock-up.








And finally...














So just the covers to pop on, but not go around to that bit and photos, so more later.

Thank for looking in!

[chief]

Hi All,

I have been a bit busy to post of late. I will try and make up for that now....

It was time to look at the small fiddly jobs. I.e the gauges. The odometer did not work for one and the actual gauges were tired. So I have embarked on a mission to make them like new and geez what a fiddle.....



As you can see, this is just one of the 50 year old gauge that has lived in California all it's life.









Taped up ready for paint inside and out.









Okay, so one down two more to go. I was a bit worried about the speedometer as when they are broke it's difficult to fix.







Fortunately it was only the 50 year old grease that had turned into coal that was causing the odometer not to work.

Lots of cleaning with brake cleaner and a re-grease and all worked fine.







Whilst putting it all back together I had a bit of an accident and ended up setting the mileage back to '000000'

I don't know how this happend.....



If you are going to attempt this just make a note of where the needle sits upon these adjustment lines with the gauge vertical.



Almost there....

[chief]

Rev counter just needed a good clean and paint. So here are the three finished gauges.





Next job was the centre console. I was replacing the factory 90mm gauges so along with the new shifter I needed to make new woodwork.







A quick mock-up to see if all matched. I purchase these in Denmark from VDO who made the original ones.

All looked fine so onto a new wiring harness to suit the new sensors.







The extra holes (2 small ones) are for the heated seat switches. The lower right is a USB output for charging phones, satnav etc.









While I was at it I have used the top bracket for the centre console to add a little bit and some 'Knee Lights' I might be able to see when getting in now.

[rhd racer]

Fantastic attention to detail as always - looks fantastic. Taking gauges apart has always given me the wobbles to be honest - even separating the rim from the body fills me with dread as invariable fill them with marks that cannot be tapped back…

Looks like the 964 has some new shoes too - looking good!


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[KS]

Such a cool project! I would never have the patience, so hats off to you!

[sladey]

Lovely work as always

[hot66]

those gauges look like new

[chief]

Thank you so much fellas. I appreciate you look in.

Okies, last update for today. I appreciate I have been somewhat behind of late....







Attention turned to the 'Blingin Stereo' with the box complete. This will be trimmed with fake straps to look like luggage.

While I was at it I started to make some speaker pods for the 6.5 inch mids down by your hoofs.









These are now satin black and fitted. However I forgot to get close up photos, so will sort some out ASAP.

Lot's still do do on this, but it has lead me onto the backpad. I need to mount speakers here so need it all mocked up to see what space I have to play with.



This is how the original looks.





New plastic panels to replace the old pressed card ones. Unfortunately they done come trimmed particularly well!







All the metal fitting were drilled off their rivets and given a clean and paint.











Lots and lots of measuring and test fitting. This has just got to be perfect....





Sort of getting there. The seats are 911 RS replicas from Cobra. A big shout out to Patrick there who even though he was on holiday and just dialing in still came up trumps. Thank you Patrick if you ever look at this thread.

This has lead me onto the seat belts and the seat sub frames.......Head scratchers both of these......!

[chief]

This weekend saw the modification of the seat frames to take the RS seats. I needed to reuse the original ones as they are height adjustable and a very cool thing to look at. The seat bases are slightly narrower that the fiberglass originals. I guess this is due in main to them being fiberglass. The RS ones are steel tube construction and much lighter than the former,

​The seat edges do sit on the frame but the bolt holes are narrower in their fitment, hence the brackets.





























I have chopped 55mm off the front end of the rails to better suit the seat. It needs to look like these were made for the car.



























Shortening the seat rail length has allowed the seat pull adjustable handle to be more easily accessible and helps with the leverage to adjust.

Just a little bit of sharpening up but all works. My concern was with the seat not sitting right above the rail would let it tilt in when you sit on them and there for foul/ jamb the sliding of the seat. Fortunately the seat does sit three quarters on the rail and the tags being much longer than needed should help spread any load issues. Not had chance to double check my theory as yet, but feel pretty confident.

The passenger frame is welded up with the bigger front brackets to help with the next bit of trickyness!