DDK - Die Deutschen Klassiker

sladey wrote:Nice work Jon - quite fancy doing that on mine sometime

May as well you are halfway there already with your rears.

Jon. You know that gearbox shortening mod, could you use that to let you move the engine and box forward in the chassis? I appreciate its a lot of work, but as and when I get the gearbox rebuilt that might be something to consider while I'm in there - would presumably need custom gearbox AND engine mounts

sladey wrote:Jon. You know that gearbox shortening mod, could you use that to let you move the engine and box forward in the chassis? I appreciate its a lot of work, but as and when I get the gearbox rebuilt that might be something to consider while I'm in there - would presumably need custom gearbox AND engine mounts

In your case as its a G50 car the gearbox nose is already forward (as its longer) so removing the 29mm from the bell housing will have the effect of moving the engine forward but the gearbox will remain in the same place, you would need to modify the rear engine support bar but the original engine and gearbox mounting points could still be used. I think the main issue would be the clearance between the engine and the bulkhead and also the relationship between the engine tinware and the engine bay seals.... Would you notice any difference in the way the car handles on the road - I'm not sure....

So as Mark mentioned I wanted to convert the car to us a G50 gearbox. This was for several reasons, mostly because I wasn't a fan of the long gears in the original turbo 4speed gearbox but also because having a G50 box installed would allow me the choice of easily fitting a 964 or 993 engine in the future If i wish.

So before painting the shell I needed to trial fit the engine and gearbox to check clearance, mounting points and also to make sure I could get the ducktail to fit over the intercooler and the bumper clears the exhaust.







It all went surprisingly well, even the original gearbox mounting holes lined up using the G50 mounting bar





A tiny bit tight here but solvable



Rear ARB also fitted nicely

The ducktail required a small cut out to clear the intercooler and also an extra opening to let air pass through it



other than that it closes down properly



The bumper also needed minimal tweaking to clear the exhaust.



although I decided some sort of heat shield would be needed to protect it from the turbo so added some fixings to the bumper for one.





Next I had to tweak the shape of the grill opening and profile of the edges a little to avoid the wrath of the DDK panel gap police at a later date

That method of using a G50 is very clever, and the bodywork looks superb. John.

Glad he's not bringing it to Oulton Park RS/Porsche Day on 11 th March, the 991 GT3's might be embarassed !

I've always felt that the 2.8 RS is where the graph peaked with the 911, IMHO it went down from that , something not rectified by Porsche until the 997 GT3.

Looking absolutely awesome, what a stunning project!

Respect

Looking great Jon, can't wait to see it in paint...especially considering the color I think you've picked...

Thanks Chaps, just pleased to get it moving forward again.

I had a few jobs to tick off before it could go into 2K primer.

I needed to trial fit the gearshift assembly



I decided to backdate the ends of the dashboard using sections cut from a scrap shell.



I had to figure out how to put a nice neat flanged hole in the rear arch, the RSR doesn't have covers for the torsion tubes so these needed to be good.

I came up with a bit of a mashup of a tool but it worked.





Gave a nice neat 5mm return on the hole





I also decided to remove the filler flap from the front wing.



And made up a section top weld in.



Then came the joyous task of rubbing down the epoxy primer to key for the 2K primer....

Excellent work Jon & great ingenuity.

What's the intended colour scheme ?

Lightweight_911 wrote:What's the intended colour scheme ?

One of these....

Impressed!

Never seen the rear torsion bar cross tube of a turbo, and did not appreciate the stiffening of the suspension mounts.
That duck tail fits well!
Keep the progress coming please. 'We' are short on rebuilds. It seems to have slowed right down with many coming to their journey's end.

As you may have noticed I closed off the fuel filler in the front wing, which meant I needed an alternative. I wasn't keen on a centre fill as I want to keep some useable luggage space and also wanted something a bit different. I like the monza style flip up fuel fillers so decided on one of those mounted through the top left of the bonnet. Unfortunately for me they aren't a nice simple round shape so creating a flanged opening in my nice new aluminium bonnet was going to be a challenge.

I made a pair of formers out of a section of laminate flooring.



Marked out the position on the bonnet, the inner one being the size of hole to cut out and the outer the finished size once the metal has been returned to make the flange.



Clamped the formers either side and spent an hour or so with the hammer!





Needs a little tidying but was pleased that it came out well without F***ing up my bonnet!





A good fit.



After a bit more work tidying and primer

Nice work Jon. Needed your big boy's pants on for that job....!