356 Speedster Flat6 outlaw build

[greg356a]

Hi Rich,
Suspension is fully adjustable so should be able to get everything looking right. The body seems to want to be moved around a lot. Similar to you, have have some wooden wedges to pull threshold out at the rear of the doors.

[greg356a]

Hi All,

Managed to pick my parts up at Sierra Madre, very helpful people and great service. Parts look great. Also now have permanently bonded and riveted the body to the chassis, and fitted the rear roll cage. Need to do some work on the drivers door b pillar to get a better alignment, but every thing else looks great. Took us longer to fit the rear roll cage on the 10 bolts than bond the body on!

[greg356a]

Morning, seem to have tackled lots of small jobs with little to show, itch, itch. I have now bonded the steel bulk head to the body, down the side of the bulkhead, underneath and around the rear/ front roll cage, also squeezed more adhesive into any area underneath to fill small gaps and clean the lines. I used 50mm wide cloth around the bulkhead which was easier and less messy than matt.

So the drivers door. Whilst bonding the rear wing into place there must have been some movement and shrinkage causing the gap to open up 12mm at worse. Gary gave some words of advice, first attempt was laughable, second attempt much better as you can see in the pics. Next need to over lay tissue and some white gel coat and more sanding, sanding.

The grey line next to the door gap shows the amount of matt that had to be added;


Of course the whole door shut needs work, sanding filling sanding. Love those before and after shots, just not done the after yet!


Front gap looking ok for a first attempt, only about 3mm, door just opens without clashing.


Don't really plan to start body work yet, but while waiting to get the electrical loom sorted;


I have made up some steel back plates and stainless front cover. The idea is to weld nuts to the steel ring and bond into place behind rear seat bulkhead and cover with a nice SS plate. Also made an access plate in the fuel cell floor to the brake master cylinder


And finally

[greg356a]

Hello, Made some progress this weekend. Applied surface tissue sanded back followed by brush applied gel coat. Really pleased for a first attempt at a new skill. Still loads of work to get the gaps perfect but a great start.

[greg356a]

Frustrating full stop. Loads of parts on back order just about stopped progress. Catches, locks, mostly seem to have half a left or half a right a bottom but not top, front lights not rear. 10 weeks is the longest back order so far and still waiting. Struggling to find a wiring loom, refurb callipers not back yet. Waiting on door packers, designed my own and sent drawing off to be laser cut, maybe next week. Still I can cut the grass

[jury]

Nice progress and nice work on the panel gaps, I know how much of a paint they are to get right ( or even half right )

Parts on back order is a pain, but you'll need something to do over winter


Keep at it, great stuff !!!

[mdmax72]

Make the most of it and double check everything you done so far?

How you doing the external fuel filler utilising fuel cell??

[mdmax72]

Just seen Pablo on hear has some door handles for grabs, here's the link

viewtopic.php?f=5&t=49850

[KS]

Be careful with the door gaps at the front edge. You'll be amazed how much they'll reduce once the door and pillar are both primed and painted.

Looking good though!

[greg356a]

Hi Guys, thanks for the pointers.
Handles - not sure whether to use a set of 911 handles I have or 356. Gary at Speedster clinic 356 handles has a second screw hole rather than the clip fit. But I could save some money
Fuel filler - really annoying that I have to make a temporary tank and chop a huge hole in the wing and plump in a pipe. Wonder if the IVA inspector would accept a sealed up bonnet?
Door gaps - Good point, not trying to get them perfect at the moment, I bet you are right. Did wonder if I should also look at fitting the door seal before paint. I know on the steel 356 doors they don't fit right unless you allow for the gasket.
Been looking at the American Autowire Highway 22 wiring loom today, looks very impressive so maybe chase down that route.
Cheers

[mdmax72]

"Fuel filler - really annoying that I have to make a temporary tank and chop a huge hole in the wing and plump in a pipe. Wonder if the IVA inspector would accept a sealed up bonnet?"

For the inspection the need access under the bonnet to check your reservoir level test and check the tank for an earth strap.

Rubber seals for doors wouldn't bother, unless you want to find which type of seal your going to use when complete. The ones Chesil supplied didn't even seal. So source my own, trial n error... Same for bonnet and boot seal.

Door handles, I never used the clip as they don't work with the fibreglass skin thickness. Just trimmed the inside area with a dremal until they slid over the skin. Really tight and no second screw required.

[greg356a]

Morning,

Rich, good point will have to use a wing or scuttle filler point with key and tether.

Wiring Loom - After a lot of research and phone calls I have ordered an American Autowire Highway 22 wiring kit and a few extras today.



The kit looks very comprehensive, 22 power circuits supported through 15 fuses and 1 circuit breaker. The circuit diagrams are very clear, colour coded etc. It will need modifying for the Porsche steering column, 911 engine, and IVA requirements. Amongst a lot of features the wires are laser printed with circuit identification every 2 inches, which has got to be good for both installation and tracking down any faults later. The kit includes a floor mounted dimmer switch anyone know if floor mounting a switch is acceptable for IVA, I guess not as it would be too much fun.

The next phase starts soon

[cubist]

Now that looks pretty good. Laser printing would have been so helpful on past projects and saved on masking tape labels! Good luck...

[mdmax72]

How easy can that be, all marked up for you. Should be a doddle...

[greg356a]

Managed a couple of hours at the weekend. Fitted the brake hose to reservoir, master cylinder, and hydraulic clutch. Need to add the IVA sticker near by. The pipe is marked up for brake fluid but put the invoice in the folder to show the inspector its suitable for brake fluid.

Also made an access stainless steel hatch to the master cylinder and pipes etc.



Second smaller hole is for the outlet for the fuel cell pipe.