356 Speedster Flat6 outlaw build

Replica owners or enthusiasts are very welcome

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greg356a
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356 Speedster Flat6 outlaw build

Post by greg356a »

Hello,
I have been lurking too long thought its about time I introduced my Flat6 speedster project. Hope you enjoy it as much as I am,
Drive train
911 2.7 complete engine believed to be 85k miles. Now a 3.2
Porsche 911SC 915 gearbox, taken from a 3.0lt SC 1983
Pair 40 Tin Zenith carbs and manifolds circa 1972 refurbished and jetted to suit.
Suspension
Front 944 S2 - 4 pot Brembo brake calipers, discs, brackets , ally lower control arms, Gaz coil shocks, anti-roll bar, 944 rack and pinion steering. 944 adjustable steering column and two link cv joints.
Rear 944 S2 - 4 pot Brembo brake calipers, discs, brackets, alloy rear trailing A arms, Uniball rear, anti-roll bar
944 steering column, rack & pinion, track rods, switch gear
General
Rear cradle fabricated to support engine, box section sub-frame underneath, radiused ribs and full roll cage to tie front suspension, door mounts, and rear cradle together.
964 pedal cluster and hydraulic slave/ master clutch modification
BBS RS three piece wheels. Fronts 205 55 16x7 ET 23 Rear 225 50 16x8 ET 11 in audi grey
Body colour options Mausgrau (Mouse grey) RAL 7005/ Eisengrau (Iron grey), classic Porsche Slate Grey, RAL 7011 Audi Nardo Grey, maybe with red triangle over top of wing and around head light.
Interior ali buckets with head rests - black and Houdstooth centre. Black/ Houdstooth side panels. Black carpet everywhere
Heated front screen E marked
Side window - manual
Tonneau cover in red - custom made for roll cage
Hard top with A posts covers windscreen post to scuttle + Paris 3 fold ragtop fitted


Pan as purchased - Start Jan 2012;
ImageIMG_2643 30-06-2011 by [url=https://www.flickr.com/photos/149951780@N05/

ImageIMG_2642 30-06-2011 by Greg Moore, on Flickr

ImageIMG_2830 by Greg Moore, on Flickr


Starting the build; Subframe cut to length and ready to tig weld
ImageIMG_2895 by Greg Moore, on Flickr



Cut out pan ready for 944 / 924 steel cross member front suspension, took ages to get right.
ImageIMG_2945 by Greg Moore, on Flickr

ImageIMG_3255 by Greg Moore, on Flickr

Rear gearbox mount, since this pic, whole gearbox has been moved forward, plate has been cut and the vw horns removed.
ImageIMG_3291 by [url=https://www.flickr.com/photos/149951780@N05/

Slave cylinder which connects to the 993 master. Drive shafts are not connected hence odd angle.
ImageIMG_3525 by Greg Moore, on Flickr

Pedals recessed forward for a little extra leg room
ImageIMG_3583 by Greg Moore, on Flickr

Cracked manifold tig with mag sent for machining
ImageIMG_3596 by Greg Moore, on Flickr

To get the flat6 to fit within the confines of the 356 body and suspension points the original torsion bars were replaced with Uniball parts. You can see that we also welded additional top and bottom plates to spread the load when the bolts are torqued;
ImageIMG_4008 by Greg Moore, on Flickr

Best tool I bought was a hydraulic scissor hoist from some mates, means you can work at any height and get underneath, really to be recommended
ImageIMG_3336 by Greg Moore, on Flickr

What is it they say? measure, measure, measure, cut, oops :oops: , weld, measure, measure at last :wink:
Image

Chassis starting to look right. Still a lot of welding to do;
ImageIMG_3752 by Greg Moore, on Flickr

ImageIMG_3753 by Greg Moore, on Flickr

:cheese: front wheels are often on the wrong sides, pleasure of working in a small 4mx5m shed and what is closest is used!
ImageIMG_3899 by Greg Moore, on Flickr

Speedster body and hard top
ImageIMG_4003 by Greg Moore, on Flickr

ImageIMG_3907 by Greg Moore, on Flickr

ImageIMG_3907 by Greg Moore, on Flickr

Body lowered onto chassis
ImageIMG_4146 by Greg Moore, on Flickr
Loads of work still to do. Now I have started this thread will try to keep it up to date

Move forward a few years

ImageGrey wide arch 356 Speedster replica JPEGS-79 by Greg Moore, on Flickr
Last edited by greg356a on Sun Nov 20, 2022 9:36 am, edited 21 times in total.
1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
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KS
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Re: 356 Speedster outlaw build

Post by KS »

Looks impressive! 8)
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andytat
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Re: 356 Speedster outlaw build

Post by andytat »

Love it!
Now Porsche less and sad.
3.2 Carrera Speedster (Sold and sorely missed)
3.2 Manual Cayenne (Sold)
73 2.4S (Gone to Singapore)
75 3.0l 914 (Sold)
Gary71
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Re: 356 Speedster outlaw build

Post by Gary71 »

Looking good so far! :)

How are the arches going to look or do you have a dramatic change of offset planned for the rear wheels?
mdmax72
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Re: 356 Speedster outlaw build

Post by mdmax72 »

Its about time we had another build thread.

Wow, like the way you moved the tranny back get the 2.7 lump within the body. Looks awesome. Keep it up.
Rich

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Evolving Speedster Build ;-)
greg356a
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Re: 356 Speedster outlaw build

Post by greg356a »

Arches :? , I have looked at so many other cars for inspiration my head hurts. I don't want just a stuck on look. So probably going to craft my own keeping the same arch flat top profile but following the natural lines at the back. A small flare at the front should be enough. Maybe something like:

Image
1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
greg356a
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Re: 356 Speedster outlaw build

Post by greg356a »

Moving the gear box back using the Uniball system was quite straight forward. Just cut, cut, cut and weld, weld :lol: Really wanted to have the engine mid mounted, sorry that's the next project 8)
1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
sladey
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Re: 356 Speedster outlaw build

Post by sladey »

impressive project
The simple things you see are all complicated
I look pretty young but I'm just backdated yeah
Gary71
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Re: 356 Speedster outlaw build

Post by Gary71 »

I'd be tempted to get it as narrow as you can from a wheel offset and width perspective to reduce the task and visual impact. It's not going to need wide wheels to handle the power output.

It will be more fun with less grip anyway!
greg356a
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Re: 356 Speedster outlaw build

Post by greg356a »

The curved sill sections are now cut ready for welding. Really like this detail
Image

Image
1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
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Re: 356 Speedster outlaw build

Post by oliver365 »

great work, looks solid ! gonna be awsome :wink:
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Re: 356 Speedster outlaw build

Post by threefiftysix »

Looks great and very ambitious which is always good in my book.
Is the 924 front suspension a first or a common conversion? Still fancy a flat six n mine....
greg356a
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Re: 356 Speedster outlaw build

Post by greg356a »

I have never seen the 924 steel cross member used at the front of a beetle pan before or it being used to support the 944 lower suspension arms. It does make for a quite simple swap. The 944 arms have been turned through 180 degrees which has been done before and apparently drives well. Once the chassis is complete, I plan to drive it around one of the local airfields so will find out then.
1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
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Re: 356 Speedster outlaw build

Post by Bootsy »

Will have to pop and have a look Since you're local - that is if you'd like me to!
1972 911T | 1994 993 Carrera | 1999 986 Boxster | 1990 T25 Camper

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greg356a
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Re: 356 Speedster outlaw build

Post by greg356a »

I managed to complete some small jobs today. Finished cutting/ shaping the rear lower bulk head steel. Preliminary fitted the windscreen surround. This involved finding some imperial 3/8 bolts (Imperial :?:), making a tube spacer and then bolting it all in place whilst laying on your back upside down! Fabricated seat supports ready to weld into place. Looks like I have a reasonable amount of leg/ head room even with the hard top on :). There is just enough room inside the main roll bar. The seat are a pair of recaro's which I will have recovered to look like an early 911 ST seat/ or singerish. I want something more supportive than the speedster style and also work with the inertia harness belts I have.

And finally some gratuitous inspiration, cant wait to hear the induction sound :lol:
Image
1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
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