DDK - Die Deutschen Klassiker

great restoration What I liked the most was seeing the inside printed in black. I would not know if it is a factory job.
congratulation!

Nice - wish my loom looked like that, at present it looks and feels like a dead tree.

How's the best ST build in Britain coming along?

Not mine Darren..! Coming along nicely thanks.

I must update the thread soon.


Dave

stretch wrote:Not mine Darren..! Coming along nicely thanks.

I must update the thread soon.

....just in case you forgot where your thread was Dave!

About time I updated this thread….!

Once the car was on it's slave wheels it was time to get on with the refurbishment of all the other parts that needed to go back on this project.
Those with a good memory will remember "Swampy" the RHD 2.2S that provided lot's of the expensive parts that are shared with the ST cars. The oil system was one of the major parts that was fairly complete but would need going through. I started by removing the freshly painted front wing to gain access to fit the oil cooler and front oil lines. Brass lines required nothing more than a good clan and paint. Flexible Cohline cooler hoses were re-hosed using new Cohline rubber and the original date stamped aluminum fittings. Big thanks to Brad Davis for the assembly tips..!

After buying 3 leaking original Behr coolers deemed "good" I decided to build a custom made cooler based on the look of the 911 R cooler. One of my leaking originals was used as a template for the mounting tabs. Original protective shroud was restored with new rubber and rivets. Everything up front ready to re-fit.

Dave


IMG_2956 by stretch1985, on Flickr

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stretch1985, on Flickr
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Next job was the oil tank and the S oil filter console. To be honest I wasn't to confident in the tank being leak free once I dug it out from storage. However, it turned out to be leak free so of it went to be ultrasonic cleaned.




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Next job, clean strip and re-hose all the oil console Cohline hoses. Experienced at this now…!
All hard lines were re-plated and with a freshly painted console the oil system was finished and ready to fit.





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The ST and other factory race cars used an oil catch tank located in the system to catch excess oil build up. The short wheel based 911 SWF branded washer bottle was the factory choice for this application. Another quirky and probably the hardest ST part to find is the Aeroquip Red cap fitted to this catch tank. This was also sourced from Brad Davis. Thanks for the gift Brad. Oil system finished and installed.


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Factory instructions for fitting of the oil catch tank.



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Dave

Hey Dave

Great update Dave, lits of helpful tips there for my build.

Come on post the next installment could do with boxing day reading material.......

Seasons greetings Mark.

Whilst I had an empty engine bay it made sense to restore and fit the fuel filter console. The locating holes on the inner panel were moved further forward during the metalwork stage. This is done to accommodate a longer electrical control board as this will now need to accept two CDI boxes for the ST twin plug ignition system. Twin coils also installed.

New filter and re-plated fittings and this was ready to install.


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Next job in the engine bay was to restore the components that would be fitted to the longer aluminum control board. Most of these parts would not be used, but I wanted to install them for a factory look. Only parts missing from the board are the two CDI boxes. I opted to have Jonny Hart's CDI + modern components installed in my original Bosch boxes. These would be fitted at a later date.

Once installed the engine bay was pretty much complete apart from the bit in the middle.


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Looking good Dave!

Next up was the Dash and all the components in the cockpit. Finding a true barn find meant that most of the dash parts were in great original condition. ST deletion items are, no ashtray, radio, glove box door, these were duly deleted. I used an original piece of basket weave material from a door panel to match in with my new radio delete panel. Very pleased with the match. On to the Gauges. Being coloured blind I didn't hold out much hope of wiring in the gauges. A blown up laminated
Colour schematic the size of a 50" inch TV didn't help either…!

Kersten took up the challenge to wire up all the gauges. Once wired up she was well chuffed when everything worked

Thanks Kersten.

Bosch pull switches were also installed to the under dash to isolate the twin CDI boxes.


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Before electrical testing of the dash controls could resume I would need to strip and restore the original snail horns. These were full of all sorts of debris and rust.

Once stripped new screws and paper gaskets were fitted. All working and fit for purpose.



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Once access to the rear of the dash was finished with, I could get on with installing the heater blower air box. As there is no cardboard cover fitted in the ST cars this would need to be looking it's best. Despite not having heat i stripped and restored the box which included plating and making new flapper plate gaskets.

20171201_122659 by stretch1985, on Flickr
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Time to finish the fuel system up front :

I decided to apply a little bit of protection to the underside of the 100 litre centre fill fuel tank. I applied several coats of gravitex stone guard using a mini gloss roller so that it didn't have a textured finish. Rubber edge trim was installed to the hood to prevent edge damage whilst filling with fuel. This trim is present on many original ST cars.

Fuel delivery would be via two MFI fuel pumps that piggy back each other. These were mounted on the bulkhead in period. Hosing up the two pumps was a very time consuming job…!


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Fabulous.