lightweight sleeper build

[coomo]

tunnel renforcement.

rear mounts


rear tube

Wevo rear sway mounts

Engine mount plates



mounts for harness

[coomo]

Rear bumper quarters were originally SWB.OEM parts that were lightly used and as new.

Obviously needed some modifications.


I wanted to use rear bumperettes.Aquired these plates,and set about making some slimmer aluminium ones.






License plate panel had to be modified

They polished up rather well.Not sure if they will ultimately stay this way though.May go brushed finish, anodised or cerakoted?

Fitted up.(before I decided on 911R lights)

[coomo]

Front bumper is an EB Motorsports unit.Ive a couple of pairs of freshly restored Hella fogs.Therefore I was going to need brackets.Found a pair of donors from an old steel bumper,and grafted them in.
Welded a bracket to inner wing,and bonded one to inner of bumper.Used some SS rod, to make a stud.One end RH & other LH thread.I can now fine tune, by moving stud in/out to get nicer gaps,and maintain tension to help seal compress.Cutout for oil cooler, with an insert to form a nice rounded edge.

[coomo]

Bonnet is a carbon one.Original hinges were a tad worn.Decided to lighten them up a tad.Then make up some new pins to restore tightness.


There will be a centre fill tank.Obviously being carbon,I cant dress the acess hole for the filler.Will be using an aluminium finisher.

[stretch]

What a great build. Enjoying this.

[coomo]

Thanks Dave.More to follow soon!

[SeanP]

Hi Paul

A great build. Glad to see you posting this up on the forum!
Still miles behind you on my build!

Sean

[sladey]

Thanks for the updates - looks to be a great build

[Lightweight_911]

.

Some nice touches - not seen anyone make their own aluminium overriders before !

.

[coomo]

Thanks for comments guys.Ok here comes another lot!

[coomo]

Now its panelled.Time to straighten out the repairs.Lead loading.Everywhere.

Notice the brown patch on rear quarter.Thats surface rust, which has appeared overnight after lead loading the repairs.I forgot to clean up with phosphoric acid.It comes off easy enough.That flux is super corrosive.(Good look if you want to do a "Patina" build)



After a while,you get this.

[coomo]

Then we move onto first coats of primer.Spectral epoxy first.2/3 coats.


The epoxy primer doesnt build at all.In fact its gets sucked down,into repairs.Its sole purpose is protection and to key substrate to following coats, and prevent any "ruck ups" (reactions) Once dry, blocked with 320 grit.
Then onto primer/filler.Thatll be me last summer.

After 2/3 coats or primer/filler.Surface gets a guide coat.(I use 3M powder) Then its gets left 48 hours.
//imgur.com/oK0HTBd][/url

Blocked again with 320 grit.This straightens out any repairs,low/high points etc.
Then 2/3 more coats,and pushed into back of workshop for a week.Once fully cured.Whole car is wet flatted with 800 grit.

[911hillclimber]

DIY rebuilds are the very best.
Lead loading, love it, and that flux is evil as you say.

Thanks for the rapid build reports, we all love a rebuild thread.

[coomo]

Onto colour.This was the most difficult aspect.Trying not to conform totally,yet not wanting to smash the bad taste barriers (Yknow like Americans can!).I finally settled on this.Its a Duraglit paint.(Max Meyer) which after a few samples chose.
Its s solid 2k.Therefore no laquer is used.(I did,but more on that later)
First was to underseal.I use this.Its twice cost of single pack.However, being 2k it covers better will never shrink crack,or fall off.Its supplied clear and tinted with colour.


Off across yard to Tonys lockup.He doesnt do anything except paint/body work.Which limits the possibility of contamination.He also keeps it cleaner than an operating theatre which helps.Hour or so later, this happens.


Under Fluorescent Lights, its Grey with a blueish hue.You may think,ok hes just used another code for Slate Grey.Its not,its way different.Colour changes in natural light.
Obviously all panels were refinished in same shade.However,I wanted some colour on engine lid.I also wanted the Porsche logo.
For this I ordered a vinyl transfer from accroman.The engine lid was finished in Orange.(think it was a Hyundai shade) Vinyl transfer applied, then painted in colour.However,this cant be done with solid 2k.Its too thick,and lays on the edges of the numerals.I had some water base coat matched for colour.Lettering removed then laquered.Once dry re flatted and re lacquered.5/6 coats.

[coomo]

Hi Paul

A great build. Glad to see you posting this up on the forum!
Still miles behind you on my build!

Sean

thanks Sean.Hardest part was discovering how to post pics.I did it years back, with 924 build,but since become computer illiterate! Ive purposely slowed down to help you catch up!