356 Speedster Flat6 outlaw build

Replica owners or enthusiasts are very welcome

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Robneal
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Re: 356 Speedster Flat6 outlaw build

Post by Robneal »

06,30 lands at Stansted at 07,30 so going to work from home tomorrow as in Manchester on Thursday

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Robneal
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Re: 356 Speedster Flat6 outlaw build

Post by Robneal »

Hey Greg,
Any chance you can email me a copy of your IVA 1C and 4 paperwork so I can check mine please?
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Re: 356 Speedster Flat6 outlaw build

Post by greg356a »

You have pm
1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
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Re: 356 Speedster Flat6 outlaw build

Post by greg356a »

Now my holiday is over, keen to get back to building.

I still had an air leak on cylinder 1 which was also the same cylinder where the manifold was weld repaired, hopefully its not porosity in the weld, and just my rough hand made gaskets. I have fitted some new manifold gaskets ordered from PartsKlassik in the USA. Really good service shipped same day as order.

The new gaskets are in the foreground and the old gasket can be seen at the back with the injection cutout
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Great fit just slipped over the studs, The back two ports show the new gasket and cylinder 1 has my hand made gaskets. Replaced all six sets.
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I also spent a long time on trying to improve the accelerator cable flow. There were a number of small issues, turns out the pedal travel did not fully open the carbs, lost bhp! The operation was not particularly smooth or light. Modified the pedal as it was clashing on the bulkhead, changed the holding brackets particularly the one in the engine bay. Operation is now light and fully opens the carbs.

The new ragtop arrives from Legacy products in the USA on Monday. Cant wait to see what its like. Its taken quite some time. Its a Custom Size Ragtop
Overall Width: 31-35" Wide, Overall Length: 20"-30" Long, Frame Finish: Black Powder Coat, Outer colour burgundy, Headliner Colour: Black Cloth, I made some accurate paper templates and sent these over. Legacy had to build a wooden buck in order to wrap the top to fit the curve template provided. As I intend to run with the hardtop fitted the ragtop should give me the wind in my face feeling but can be closed to make it water tight. hopefully Legacy will remember to send some colour swatches so that I can get the seat belts to match the same colour.

Now looking at paint. Started to get some quotes and talking to various shops. What a nightmare, how do you know who to chose? Prices is import but quality of finish, and willingness to fix any issues in paint all seem to be difficult to judge. Also think it is important to be local so I can asses progress. Not fully sure on the merit of selecting a company familiar with GRP. Live near Lotus so local shops all seem to have an ex-employee who paints GRP.
1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
greg356a
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Re: 356 Speedster Flat6 outlaw build

Post by greg356a »

So new ragtop arrived looks fantastic, really pleased with the quality and colour.

I have spent 4 hours plus trying to find centre of the roof both by measurement and by eye then drawing out the cut hole. I think its right but you only get one chance so decided (chickened out!) not to cut today. Plan to check all the measurements yet again and then break out the angle grinder. The diagonals are within +/- 1mm

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until another day
1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
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Bootsy
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Re: 356 Speedster Flat6 outlaw build

Post by Bootsy »

Yes, check and check again!
1972 911T | 1994 993 Carrera | 1999 986 Boxster | 1990 T25 Camper

Vintage Heuer, Omega, Zenith and other vintage watches - http://www.heuerheritage.co.uk
andytat
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Re: 356 Speedster Flat6 outlaw build

Post by andytat »

Measure 10 times, cut once!
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)
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Re: 356 Speedster Flat6 outlaw build

Post by greg356a »

Maybe this is the first speedster fitted with a ragtop?

I must say the Legacy product from the states is very good quality with good instructions including several videos. Its very simple in design but just works with ease. So hopefully I have a distinctive hardtop with the practicality of the coupe (almost) and weather like this weekend just go topless 8)

So after measuring several time (lost count) I have cut the hole!
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I took a tip from Rod Emory and fitted the top forawrd to give a more wind in the face feel.
First lay of the frame into the hole, and its the right size. There are several studs around the aprimeter that holds it off the roof. These all have to be measured and the roof accurately drilled.
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Then the whole top has to be taken apart, mark the position of the studs ready for fixing. Then just a case of working through the process
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Very pleased with the first result. Plan to tweak the angles at the corners slightly to allow is all to sit down a little flatter, dont think water ingress will be a problem - fingers crossed.

Also spent another long few hours on the accelerator pedal, cable and connection with the carbs. All very fine adjustments but it now seems to work smoothly and operates full action of the carbs. Looking at tweaking the advance curve setting to get acceleration smooth flat spot at around 2000 rpm in first
1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
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Bootsy
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Re: 356 Speedster Flat6 outlaw build

Post by Bootsy »

:cheers: :cheers:
1972 911T | 1994 993 Carrera | 1999 986 Boxster | 1990 T25 Camper

Vintage Heuer, Omega, Zenith and other vintage watches - http://www.heuerheritage.co.uk
911hillclimber
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Re: 356 Speedster Flat6 outlaw build

Post by 911hillclimber »

Excellent!
Did the very same to my 73 911 in1989.
Looks a good job done.
Mine has never leaked a drop since then. :)
73T 911 Coupe, road/hillclimber 3.2L
Lola t 492 / 3.2 hillclimb racer
Boxster 987 Gen II 2.9
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Re: 356 Speedster Flat6 outlaw build

Post by greg356a »

The ragtop is water tight! 10 mile drive in the poring rain this morning not a drop of water, well from the ragtop anyway.

Organised to lower the car a little further. Thought it sensible to lower and then drive it, then lower again. At the moment its 10 mm down and I think I can go around 10 - 20 mm further. Not a fan of in the weeds or having to be too slow/ careful over lumps and bumps or overly compromising the suspension and ride quality.

Also spent a few hours in the week dismantling, cleaning, lubricating the gear shift linkage and reassembling, now have all five gears which are now easy to select. I know the 915 reputation is not great but seems to slip into all five without drama. The throw is very long maybe I will have a look at that in the future.

So on the drive back took the opportunity to push the acceleration - wow, wow fastest car I have ever driven. Looked in the mirror and the jag had disappeared only to appear when I got stuck behind a tractor. Engine pulls very strong from 3000 rpm. I still have some hesitation at 2000 to 3000 rpm, next on the list is the valve clearance. Read on Pelican parts that zeniths really like small air correction jets. Stock was 185 I am running 180. After valve clearance is set will look at going down in size further


I have tried several times to calibrate the fuel gauge to read full/ empty correctly but absolutely no luck. I have spoken with Zach over at Safe Cell who has organised for another sender 7" and 76-6 OHM which should be the answer.

Also order two pairs of belts, one for the bonnet and one for the boot. Found a guy in the UK who makes them to order with buckle pad (protect paint) at a fraction of the price from the USA. Will update everyone when I receive them. Just hope they are as good as they look

Spent time with Aaron at LA Custom coatings to talk about going to paint. Colour choice is going to be tough. Slate grey / Nardo grey / Graphite blue (Porsche latest colour) usually are top three but not always in the same order.

ImageIMG_3103

ImageIMG_3109
1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
greg356a
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Re: 356 Speedster Flat6 outlaw build

Post by greg356a »

Really pleased with my new bonnet and boot straps from Jim. They are top quality leather, stainless steel buckles with the back pad to stop scratching the paint work, all at fraction of the price they want in the USA.

ImageIMG_3226

Just need to work out what angles to fit them at. Any ideas?

http://www.bonnetstraps.co.uk
1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
greg356a
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Posts: 860
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Re: 356 Speedster Flat6 outlaw build

Post by greg356a »

Spent a few hours in the garage positioning the bonnet and engine lid straps. The easiest and most accurate method seemed to be to string them from a central point

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Waiting on delivery of the M4 rivnuts to finish off but the lines, angles all work for me.
1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
greg356a
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Posts: 860
Joined: Sun Mar 25, 2012 9:16 am
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Re: 356 Speedster Flat6 outlaw build

Post by greg356a »

One project which I never saw coming was re-sculpting the hardtop's lack of flowing lines between the rear 1/4 window and the door line. I guess the hardtop was moulded around a rear 1/4 screen and glass that perched on top of the door. So the result with wind-up-windows was a rather ugly step

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So loads of cardboard cut outs and moulding clay and decided I could make it look a little better

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Match both sides

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The rear 1/4 glass now end level with the door glass and should butt up nicely with the aid of a small clear bubble gasket to seal against the weather.

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I have designed some new stainless steel rear 1/4 frames which have been sent for laser cutting and also ordered some new Plexiglas

Was hoping to get one last drive in today before I start stripping everything off ready for paint in November.

Rain stopped play!

So just some quick pics;

Belts now fitted correctly front and back

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Mohican look;

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1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
mdmax72
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Re: 356 Speedster Flat6 outlaw build

Post by mdmax72 »

Can’t believe you used that word PAINT... shame on you lol. Won’t ask the colour of choice will wait with anticipation.

It’s these small details that get to bug you. Nice to see it progressing though.
Rich

DDK Member 0547

Evolving Speedster Build ;-)
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