356 Speedster Flat6 outlaw build

Replica owners or enthusiasts are very welcome

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greg356a
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Re: 356 Speedster Flat6 outlaw build

Post by greg356a »

Hi Richard,

Yes will be using the 944 as the registration donor vehicle
Two major components will be front and rear suspension and steering assembly, with officially a new chassis from a specialist kit manufacturer/ SPC
Hopefully the registration number will be based on the age of the original vehicle. Actually after the last countless years of dreaming and 6 years building a Q plate would not be a problem. Just means its made of different age parts which it is. I doubt most passer byes know what a q plate is, probably think is an old car :?

I have never intended the car to be a complete accurate replica, but more a case of what Porsche might have done if they carried on making the 356 model. Race inspired Big flat 6 engine, ST/ Turbo arches, stripped interior, huge brake stopping power, low cg, improved suspension. All noise and impression of speed. I saw my first 356 California widebody replica about 20 or 30 years ago at Newark kitcar show and now finally getting close to having my own.

The build thread really is a useful to document for what is a very personal journey. Record ups and downs, elements that went really wrong like my handbrake and elation first time I heard the flat 6 fire and run. A tool to think about what you want to do or not with your car etc. Also helps when you look at how much you have actually achieved over time. I find it spurs me on to get some work done so I can get an update on here. It is surprising how inspiring a "looks good/ well done" is. :)
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 »

Productive couple of nights, just down to a handful of issues now
Voltage Regulator over charges at 17v on high rev
Hand brake warning light finish wiring off
Heated screen switch working & light - works just needs final switch/ wire fix
Engine Oil Cooler to be replaced to cure leak
Hand brake cable adjustment
Metal strap over fuel cell and under leather belts straps.
Mock MOT to reveal any last faults.
:)
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 »

Diminishing list continues, but had a last minute problem;

Windscreen is marked with a quality British Standard mark but needs to be an EU mark - nuff said! So removed screen and ancillaries, now looks like a track car :) Looking forward to flies in my teeth 8)

So from the last list just need to complete the mock MOT and fix any issues

but some new to do items seem to appear;
HT leads need replacing with a set that has the manufacturers mark every 120 mm or less. This is to cover electromagnetic suppression / interference.
Passenger door latch has stopped engaging correctly. It seems the brand new Brazilian VW latch has broken. Will change to an original 50 year old German unit.
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 »

Back to the usual story; two steps forward one step back!

The great news is that I drove the speedster up and down a private 1/4 mile lane on Tuesday. The first drive was fantastic, loads of power, acceleration and flies in my teeth because of all the smiling :) . Really surprised how well planted the car felt, turning circle was much better than I thought, sense of acceleration due to the induction roar exhilarating.

The down side, started to struggle to get 2nd gear. In the end no other option the box is going to Mike Bainbridge on Friday. The car pulled from stop in 1st, 3rd and 5th. Reverse gear no issues. I guess the power to weight ratio meant you could pull away in any gear

So more delays but really satisfying to drive a car which you have built yourself.
1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
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Re: 356 Speedster Flat6 outlaw build

Post by Bootsy »

Must have felt great. Hope the gearbox is nothing major
1972 911T | 1994 993 Carrera | 1999 986 Boxster | 1990 T25 Camper

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Re: 356 Speedster Flat6 outlaw build

Post by mdmax72 »

Great news after all these years tinkering you got to give it a 1/4 mile blast.

Is it the gearbox that’s at fault or your selector set up. I do recall the late Ian having problems until he upgraded his selector set up. Can’t recall what he went for in the end. Will be on here if you dig through the pages.
Rich

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Evolving Speedster Build ;-)
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Re: 356 Speedster Flat6 outlaw build

Post by greg356a »

Unfortunately the gearbox is the issue. Even if you only operate the selector shaft 2nd gear cant be selected. The 40+ year old box was second hand with no guarantees so hands up should have invested the money earlier to have it repaired. In my defence initially you could select all 5 gears.

Having worked late Thursday night to remove the box ready for collection, the delivery company failed to pick up on Friday so further delays, very frustrating. From the beginning I tried to make everything accessible. the top nut on the box was a little difficult but everything else was straight forward.

The 1/4 mile blast was very helpful learning how the car worked and felt, one of the very last items on the electrical list was the speedo not working, whilst the box is out again I plan to replace the sensor just in case.

PS: notice the delivery company got paid ontime!
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 »

Ok, one of life's conundrums, buy another 915 transmission or repair? I decided in the end to go with repair simply that I would have a box which I had some knowledge of rather than another said to be "running box" Maybe later on I can find another box if I need to.

Exhaustive repair parts;
Parts list for gearbox No 317
1X 915 300 911 01m gasket set
1X 915 302 282 00 pinion nut
1X 999 034 033 00 input shaft nut
2X 999 201 470 00 loose gear bearings
1X 915 302 301 04 2nd syncro band SC/3.2
1X 915 302 301 06 1st syncro band SC/3.2
1X 1st gear dog teeth
1X 2nd gear dog teeth
1X pinion roller bearing, Large O/S outer at 80.
1X 1st/2nd slider, late SC/3.2
1X 1st/2nd spider, late wide drive
1X S/H 2nd gear set
Plus 4 speedo magnets

Many thanks to Mike Bainbridge for all his help. If all goes well another step forward next Monday when I refit the box

Warts
ImageIMG_8731 by [url=https://www.flickr.com/photos/149951780@N05

ImageIMG_8746 by [url=https://flic.kr/p/26vwA9h]ImageIMG_8747 by Greg Moore

ImageDog teeth mising by [url=https://flic.kr/p/26vwAxJ]ImageMaganets missing by [url=https://flic.kr/p/26vwAH3]Imagerust on the crown wheel teeth by [url=https://flic.kr/p/KttqtN]Imagepinion roller, outer race coming out with the gear set 8773 by [url=https://www.flickr.com/photos/149951780@N05/]
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 »

Transmission breathed on by Mike and fitted with lots and lots of new and second hand part, collected yesterday ready for fitting tomorrow

ImageIMG_8804

ImageIMG_8803

Many thanks to Mike for a very professional and speedy services
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 »

Gearbox fitted and filled with EP90 oil. Quick 1/4 mile blast gave 1st, 2nd, 3rd, 4th and Reverse. Need to fettle a little to get 5th. Next step complete an MOT to reveal any issues we are not aware of.
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 »

Yesterday was the big moment after 5 years of building, countless hours of planning/ dreaming was all the effort going to meet the approval of the IVA inspector?

So early start car on trailer and off to Norwich IVA centre on Jupiter road. Arrived 15 minutes early not quite sure where to go. Fortunately people pointed in the right direction.

So Ian was our examiner for the day who made me feel at ease from the start with a cup of coffee and a chat, however he did politely point out that most people don't pass first time. The test started at 8 am with Serial numbers and VIN chassis plate checks to match the paperwork. Emission were next before moving onto the four post. After a thorough check underneath and lots of "Not seen one like this before, its cleaner here than on top" we moved back onto the flat for a full electrical and measurement check. We were introduced to Jason the mechanical driver who does the seat belt height and head rest checks.

So brake rollers next: fronts 197 left 197 right "we don't get that often" perfect balance. Then the back brakes and the dreaded hand brake. Fingers crossed on the hand brake which has been the plague of the whole build. Numbers looked good to me.

Next set of rollers were described as seeing if the car will do 70 mph. Straight into fourth pull away on the rollers straight up to 70 on the speedo gauge and electronically measured rollers at 65 mph so that's another tick

Ian took the speedster for a drive around the car-park checked the steering self centre and weighed the car. Now onto mirrors and sound emission. So with a standard 911 exhaust thought all was going to be well. The limit is 99db and I reached 99db at 3/4 revs so another tick - just

Ian left us at this stage to entered the weight into the computer to check the front/ rear balance and comparison against the design axle weights given. Fat boy at 1040kg

Ian came out with a big smile and congratulated me a first time pass!

Really struggling to believe I passed but I have the IAC certificate to prove it.
Last edited by greg356a on Thu Jun 14, 2018 1:07 pm, edited 1 time in total.
1963 Karmann Ghia
1959 356A Coupe Outlaw
1957 3.2 Speedster replica
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Re: 356 Speedster Flat6 outlaw build

Post by porschewagen »

Well done. What an absolutely fantastic result and no doubt you are thinking it was worth all the blood, sweat and tears now! Enjoy your car.
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Re: 356 Speedster Flat6 outlaw build

Post by Bootsy »

Superb, that's a hell of an achievement and a great example of how to build for IVA
1972 911T | 1994 993 Carrera | 1999 986 Boxster | 1990 T25 Camper

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

Post by cubist »

Just caught up with the last few pages... What a fantastic result. 10/10 on the pass first time!
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Re: 356 Speedster Flat6 outlaw build

Post by mdmax72 »

Well done again Greg, first class...

So with this chapter at an end and you think it’s all over, Now chapter two begins. The rebuild...

Enjoy
Rich

DDK Member 0547

Evolving Speedster Build ;-)
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