Birth of a rally car

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pht9
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Birth of a rally car

Post by pht9 »

Over the coming months, I intend to document our build of a tarmac rally car that will be presented for FIA/HTP papers, as a 3062 homologation 911SC

A bit of background to start.

My Company, Tech 9 Motorsport has been actively involved in Motorsport since 1993, solely circuit racing, and primarily with Porsche, although we have had a few different championships and marques prepared over the years, our experience was generally with Porsche models from 964 all varaiants, through to 993 Cup/RSR/GT2, 996 GT3 and turbo and latterly 997 in all its racing forms. The downturn in the economic climate was a factor in my decision to halt circuit racing, and concentrate on our core business which is tuning, modifying and servicing Porsche from our workshops in Liverpool.
I stopped racing personally at a competitive level in 2005, and concentrated on the running of what became a rather large race team, we would quite often run 4 cars at an FIAGT meeting, and the staff and logistics involved in this were quite something !, anyway, as the race team is not operating, I feel that this is a chance for me to get back behind the wheel, as the roots of Tech 9 were based around my racing activities, and here was the chance to return. I thought long and hard about what to prepare and what to enter, I wanted to build a car, and considered all forms of 964 or 993, but didn’t feel that there was a championship that I felt motivated to enter, I then considered ‘historic’ events, and pondered over a ’74 3.0 RS, or even a 2.0 ’65 car for a brief moment, but I did not like the idea of being mid-field in events, or a class winner, so my attention turned to historic tarmac rallying. Here is a discipline where a well driven Porsche can win outright, and I feel it would be a good environment to showcase our technical ability and the standards that we operate to build a ‘new’ historic 911. The car will also act as a showcase for products and services that we will be able to offer to our clients, especially some of the ‘period remanufacture’ parts that will be used.

So, having decided upon the discipline, a suitable car and specification had to be finalised. I really like the look of a ’74 3.0RS or RSR, but felt that a wide body car would not be as agile or nimble as a narrow body. I had in my mind the mechanical specification that I wanted to build, a 3.0 MFI engine was at the heart, so decided upon the 3062 homologation pre ’81 911 SC.

Next step, find a car !. I looked at a few cars, needed to be an SC, I wanted LHD wasn’t really bothered about the mechanical state, but wanted a good standard chassis with very little rust. This is helped I suppose by the fact that post ’76 the chassis became galvanized, so as long as the car had been generally looked after, then my search should not have been to difficult.

Anyway, after a couple of months searching, The perfect donor was presented – A 1978 911 SC, that was converted by RUF in the eighties to ‘SCR’ specification. I did ponder about the fact that this car was relatively rare, and that should I be stripping such a car. Taking a view on the actual car, it was very tired mechanically, the engine had serious cylinder leakage, the gearbox needed rebuilding, the bodywork was rather scruffy, in that it had been painted badly during its life, and had lots of areas of corrosion in the bolt-on panels, but structurally (must have been all the engine oil sprayed on the underside !) the chassis looked fine, and some period parts could be re-ued in the build, such as 930 brakes, ZF LSD and I was quite surprised to find OE spec manual window operation !. To restore this car to its former glory, would not have been economically viable, so the bullet was bitten, and the build began – or rather the strip began !

RUF 911 SCR

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Post by Gary71 »

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RUF SCR Rear by techninemotorsport, on Flickr

Interesting project. Keep us informed! :)
pht9
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Post by pht9 »

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Post by pht9 »

a cold december winter morning, and she is stripped and off for dipping

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pht9
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Post by pht9 »

chassis returns from dipping, pretty impressive the condition, considering she is 33 years old !

Only real areas of corrosion were the top and bottom of the door lock posts, plus some unsightly repairs to the left rear quarter. The great thing about dipping is that it uncovers everything, it was obvious that the left rear had been repaired, but I was surprised at the amount of filler that must have been used !

We now have a perfect surface to commence the chassis strengthening, and modifications that will be required for its future punishment...

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Last edited by pht9 on Fri Apr 22, 2011 9:20 pm, edited 1 time in total.
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Post by bjmullan »

I will watch this one with interest. Lovely colour of green 8)
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Post by Nick Moss »

Hi Phil

The guys at SPL told me that they had done your car recently (I think it was the first 911 though their new process) when I dropped my 3.2 shell off with them the other day. It looks to be a fantastic project, and a concept close to my heart. You should consider posting this over on impactbumpers.com, they would love this project too.
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Post by Dakota »

Hi
is the "new" process a version of acid dipping and will you have to replace the heater "silencers" inside the sills?
I am a person of simple pleasures so if you don't have any simple pleasures to offer me, beer, pizza or Porsche bits etc kindly leave me be, XX.
pht9
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Post by pht9 »

nick-moss wrote:Hi Phil

The guys at SPL told me that they had done your car recently (I think it was the first 911 though their new process) when I dropped my 3.2 shell off with them the other day. It looks to be a fantastic project, and a concept close to my heart. You should consider posting this over on impactbumpers.com, they would love this project too.
thanks nick, will consider posting on IB too !

look forward to seeing your project taking shape in the future
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Post by pht9 »

Dakota wrote:Hi
is the "new" process a version of acid dipping and will you have to replace the heater "silencers" inside the sills?
the bodyshell is acid dipped.
As my car will be for competition use I have decided against a heating system (I know not smart in the winter months !) so the heater ducts in the inner sills were removed prior to dipping as they make a mess in the tank.

If it was a road car, its not too difficult to remove the ducts and replace after the process

You can see from this picture a hole in the inner sill section where the duct was removed, then the panel welded back into place after dipping.
This also gives good access for the e-coating process which is done after all the chassis work is completed

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Last edited by pht9 on Fri Apr 22, 2011 9:13 pm, edited 1 time in total.
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Post by 911hillclimber »

Is it just me or is this shell in fabulous condition?
Does the dip remove any zinc on the steel?

Nice project.
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Post by dragonfly »

Great project, I look forward to following your development of the car.

Another vote for posting on IB too. There was a discussion about your donor when it was for sale some time ago, so they'd be v interested to see the next chapter of its story

Edit: The thread with some history of the car is here: http://www.impactbumpers.com/forum/inde ... topic=2296
Last edited by dragonfly on Wed Apr 20, 2011 10:16 am, edited 1 time in total.
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Post by Bruce M »

That shell looks pretty good.

It is a shame the car couldn't be preserved in it's "original" state as a Ruf conversion but I can understand the costs would completely swamp it's final value.

Perhaps as a nod to its history you could keep the Ruf badge on the bonnet.

I remember a number of years ago, a magazine did a small feature on a LHD green Ruf SC with a roll cage. It was described as a "RSCR" and had a different (non ruf?) front bumper/spoiler. Priced at £13K if I remember correctly. Is this perhaps the same car?
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Post by Highfield »

Nice project Phil and one to watch.

You have PM re: 964 suspension !

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pht9
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Post by pht9 »

911hillclimber wrote:Is it just me or is this shell in fabulous condition?
Does the dip remove any zinc on the steel?

Nice project.
agreed, the bodyshell is in fabulous condition, when SPL dip the chassis they also apply a rust preventative coating, which will offer some short term protection.
If no further modifications were to be done, it would be important to get the chassis into a bodyshop immediately for primer and paint, as the metalwork would start to rust again over a period.
As we will be carrying out extensive bodyshell modifications over a period of 4-5 weeks, once this work has been completed, the chassis is re-dipped, which will ensure any corrosion that has started is deleted, then e-coated, which will then give it the maximum protection and a good base.
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