21st Century Outlaw 997 Project

[hickepa2]

As you’ve asked; stay retro, keep them solid.


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[hot66]

Think I like the solid look


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[chief]

Darren, just read through the whole of your amazing thread. Very, very impressive sir!
Embarrassing, but didn't even know of this 'Restoration' section. It was only reading Stephen's 914 thread being moved here that I noticed. I am now firmly planted here!!
There are truly some inspiring builds here.

[DustyM]

Solid for me too.

Amazing work.

[rhd racer]

+1 for solid Darren.

An incredible build, loving it

Cheers
Wayne

[bjmullan]

One more for solid. Just great bedtime reading.

[tim69s]

Hollow, in Carbon Fibre, mix of traditional and modern, which I think fits exactly what you are doing with your car.

I have access to a 3D printer if it would help with prototyping Darren. And live 5 minutes from you.

Can’t wait to see your car(s).
Tim


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[Darren C]

Thanks Tim, that's good to know, may take you up on the offer for other stuff.
I'm avoiding Carbon Fibre on this particular car as I want a more retro look (brushed stainless/Fuch rim sympathetic matching) rather than the Singer Williams rendering, don't want too many materials/colours in the mix

Where are you based?

[dragonfly]

Hi Darren, I've just spotted this thread and read through. Wow, what a project and fantastic skills.
I will follow it with interest and keep an eye out for you around the neighbourhood

[sfl993t4]

Very impressive work, keep the pictures coming!

[Darren C]

Thanks again for your support in this new found territory

I'm going to bring you up to date with the exhaust idea I had (part shown earlier in the "what did you do on your Porsche...." section.

Please bear with me as I upload pictures (since PhotoFucket, I haven't found a host yet, so loading directly to DDK to hopefully futureproof?) It'll only let me post 3 pictures per post due to file size, so it may take me 4 or more posts to tell the story of the exhaust so far. Comments most welcome at the end

So, I wanted to do something different for an exhaust on the 997 Outlaw, and in selecting the 991 bumper valance insert with the split centre pipes, thought about a Stinger (some folks call em intercooled- which I hate) tip.

bumper14.jpg

stingerexhaustX.jpg

But obviously the whole system on a 997 Gen 1 Carrera S is completely different to aircooled with split back boxes. I'd already opted for the Eurocup full flow stainless system when I did the engine build, so would need to work with that.
Having thought about this over a year ago I saved £300 & didnt buy the Eurocup tips, but simply modified my original ones and had to temporarily tack weld them on to the car to get up & running (knowing it would all be cut off, once the bumper was done)
After purchasing the 991 insert piece in pic1 above I now knew the centre spacing of the pipes & what diameter I could work to that best complimented the openings.
The next job was to work out where to cut back the Eurocup system (after the CAT's & boxes) so that I could re-plumb to the new twin opening in the valance.
I decided on imagineering a brace link to sit hidden behind the bumper but act as a permanent bracket & support for the relocated/plumed Eurocup pipes.
I knocked up a quick drawing

brace4X.JPG

Then added (just because) a script for 21st Century Outlaw through the middle

[Darren C]

The file got converted & I laser cut a few in 3mm stainless just in case.

Trouble was, with such a fine script (that had taken ages to match Porsche font) the laser filled the letters with slag which needed digging out, then with watchmakers files & finally sandpaper, cleaning out

brace3X.JPG

So after several nights in the shed the letters were clear & I added a brushed finish.

brace2X.JPG

The outer ends have holes the OD of the Eurocup pipe so fed inwards from left & right I plan on welding the pipe into the link bracket. The larger OD on each end fits nicely inside my outer tailpipe tubes.
So the next hurdle was folding up the sides to add strength to it. With the two round ends it wouldn't fit in my folder
There goes another week making a form tool!
Anyway got it all done in the end

bracket finX.JPG

[Darren C]

Looking at the stinger ends in photos on line over a range of Porsche inc 904, it did seem a little crude for what I was planning.

Over the last year I approached Fifteen52 about making a billet wheel for the 997 (that's before I found the Sports Classics) but my nose was a bit put out by the chap on the phone (yes I called the USA to discuss) "Sorry but you wouldn't be able to afford the R & D" was the answer Don't they know who I am?

Anyways, the cutout petal design Fuch got me thinking....
What about that as a Stinger homage & an Outlaw homage all in one sensory engineering overload

So off to measure Eurocup pipes & work out cross sectional areas to find out what scale they needed to be to have the openings be equal to or greater than the Eurocup full flow pipes.
First renderings looked like this..

CAD wheel 2X.jpg

But I gave the design a tweak to increase the open area even more & finished off with this without compromising the Fuch look. And then just because I can, I changed Fifteen52 to a split rim

CAD wheelX.jpg

So again the file got split into several components to make up a 3 dimensional object & converted for the laser. Again as insurance I came home with a box of stainless steel goodies

bits.JPG

Unfortunately at this scale the laser definition (cant do 2mm holes, only etch the position) was not good, so many weeks, yes WEEKS were required with the swiss files to clean all the parts up

[Darren C]

Soldiering on with the rod for my own back, I cleaned up 4 (only needed 2, but made 4) of the centre base plates.

wheels makeX.JPG

Each one has 35 x 2mm holes, thats 140 to drill by hand through the laser etched slag suffice to say I did break a few drill bits

Then I started to turn the rim section on my lathe from 6mm thick stainless to match a fuch profile.

Rimturning1X.JPG

RimturningX.JPG

This was interesting as it got a harmonic going (like a finger around a wine glass rim) which made it hard to get a good finish.
I cracked on and then...yep had to drill another 140 x 2mm holes ACCURATELY in the rim to match the centre.

[Darren C]

The raised petal section of the piece came next. These needed to be swiss file fettled like the centre & had to have every opening individually filed to match exactly their respective centre & hopefully interchangeable between all 4 if I got it right

wheel assemblyX.JPG

As this needed to be permanently fixed together on the car I opted to MICRO Tig weld them (no rod, just fuse weld, each weld is about 1.5mm wide!)

tig2X.JPG

This was done inside the openings on each side of the triangular holes (3 welds per hole, 15 per centre)

In the meantime I tracked down some stainless M1.6mm socket head bolts to hold the rim to the welded centre.

M1.6 2X.jpg

These were "kin" tiny