DDK - Die Deutschen Klassiker

Hi Rich,

Yea know what you mean I guess all projects have areas which just have to be redone twice or three times or four times!

So the handbrake cables have gone off to Cable-Tec in Ellesmere Port to be re-made.

Must say their communication and response has been excellent so far.

Hey Greg

That’s the thing with these cars when modifying. Nothing is off the shelf with all the R+D already done, which is part of the fun for me al least.

Yep, actually the best part. I know the car will drive like crap, accept the first full road drive which will be miles of smiles irrespective of the ride quality! I hope to get some time on the car soon and get it ready for IVA. The To Do list is getting much shorter!

Way to go I now have a working handbrake!
So on the nth attempt it all now works as it should. I have used the standard non-modified Porsche 944 turbo connectors at the hub end and standard but M8 at the Beetle end. So the fix was really simple in the end, I used a bracket on the vw horns which can be removed for servicing and a shortened modified Porsche 944 style cable. Cable Tech have done a great job supplying the correct parts. This is now one of the few non-Porsche or OEM parts on the car but given the beefed up cable thickness and connectors it should last.
Moving on to the door cards next, then back to the IVA boring stuff prior to the test.

Difficult to get the best "all in black" photo on your I-phone but hopefully it shows the bracket and hand brake cable

IMG_1594 by Greg Moore, on Flickr

Top marks for not letting it beat you Greg. Nice job

The first drivers side door card is fitted, the build pics follow;

Hard board panel cut to size and wrapped in foam and correct Porsche vinyl
IMG_1559 by https://www.flickr.com/photos/149951780@N05/, on Flickr

IMG_1560 by https://www.flickr.com/photos/149951780@N05/, on Flickr

IMG_1561 by https://www.flickr.com/photos/149951780@N05/, on Flickr

I used M6 blind rivnuts on the doors to provide a period look
IMG_1604 by https://www.flickr.com/photos/149951780@N05/, on Flickr

IMG_1605 by https://www.flickr.com/photos/149951780@N05/, on Flickr

The hounds tooth pocket sawn up
20170601_125857_resized by https://www.flickr.com/photos/149951780@N05/, on Flickr

IMG_1618 by https://www.flickr.com/photos/149951780@N05/, on Flickr

Panel fits but will need some adjustment
IMG_1616 by https://www.flickr.com/photos/149951780@N05/, on Flickr

Plan is to finish off the adjustment and then move onto the passenger panel. Hopefully can use some of the tricks learned when making the first one

Nice

Another update on a slight backward step
I originally fitted the seats to some really nice aluminium brackets which I spent ages manufacturing and having powder coated. The runners I used were from a pair of donner Recaro seats which again worked fine. However, the passenger seat which used the original drivers seat runners had a lot of play allowing the top of seat to pivot, which I am worried would fail the IVA test. So I have bought a new pair of runners from Car Builders Solutions. Working through the process of accurately measuring each runner so they are parallel to each other and slide easily. I am also taking the opportunity of fitting the seats lower in the car, the lovely ali brackets have gone replaced with steel angle welded directly to the runner. Ugly but almost invisible when installed.

Picture of one runner with angle steel, high at the back to achieve a better seat angle for the fixed back buckets
IMG_1654 by https://www.flickr.com/photos/149951780@N05/, on Flickr

Picture of the handle for the double runner lock which needs widening
IMG_1655 by https://www.flickr.com/photos/149951780@N05/, on Flickr

Also really excited to see the BBS RS wheels fitted now they have been finished in the Audi LAU8 code colour. They now look perfect
IMG_1625 by https://www.flickr.com/photos/149951780@N05/, on Flickr

IMG_1624 by https://www.flickr.com/photos/149951780@N05/, on Flickr

The interior is starting to look a little more finished

IMG_1658 by https://www.flickr.com/photos/149951780@N05/, on Flickr

IMG_1659 by https://www.flickr.com/photos/149951780@N05/, on Flickr

IMG_1660 by https://www.flickr.com/photos/149951780@N05/, on Flickr

IMG_1661 by https://www.flickr.com/photos/149951780@N05/, on Flickr

IMG_1662 by https://www.flickr.com/photos/149951780@N05/, on Flickr

IMG_1665 by https://www.flickr.com/photos/149951780@N05/, on Flickr

Excellent work!

Thanks Keith

So I have been crossing jobs off the list including the last big job - windscreen. Slightly worried about cracking the screen because its so cold in the garage, I guess glass must be brittle when its cold.

Started inside the house in the warm by using a masking sealing adhesive to bond the gaskets in place and used load of trusty pegs to keep everything tight around the curves

IMG_1676 by https://www.flickr.com/photos/149951780@N05/, on Flickr

IMG_1675 by https://www.flickr.com/photos/149951780@N05/, on Flickr

Getting everything in the right place takes time and patience of which both are limited in the cold;

IMG_1680 by https://www.flickr.com/photos/149951780@N05/, on Flickr

IMG_1688 by https://www.flickr.com/photos/149951780@N05/, on Flickr

IMG_1685 by https://www.flickr.com/photos/149951780@N05/, on Flickr

Speedster gone off for an MOT and some electrical issues that occured over the winter in the garage. Obviously I need to go through the full IVA test but the MOT is a good starting point to check general build condition and operation + its not too expensive!

I had some 15mm spacers on the back wheels to fill the arches which made it too wide for the trailer So they have been removed, and left off for the IVA test which will ensure no arch fouling issues.

This list is shown below;

Adjust Handbrake cable tightness
Engine emission metered at CO <= 4.5% / HC <= 1200ppm. The exhaust must not emit excessive smoke or vapour of any colour during acceleration which would obscure the view of other road users.
MOT to check everything, nyloc’s everywhere. cables, pipes all secure etc no chance of rubbing anywhere/ full lock etc, brake force/ balance, handbrake 18%, door locks, belts, 99dba exhaust, Head light aim.
Wiper self park – Not working, parks anywhere
Ignition switch does not turn off on the key - spring at back of switch
Electric windscreen switch for heated/ Wiring Kit, 10 min delay relay – wire up please?
Brake fluid warning light needs to be on own indicator switch/ light - Add next to H/Brake switch - Move H/Screen switch
Front day time running lights – Not working
Tach – not working
Speedo – not sure if working or not check running around the yard
Side lights Front/ Rear/ number plate light – Not working
Oil warning light - Not working
No other electrical issues

Can i ask how you are going to get your speedo calibrated for iva. I thought i read it needs 3rd party certification?

Using exactly same unmodified 915 gearbox & sensor, same size tyres/ diameter as the original 911 the speedo came out of, so should be within tolerance as permitted in section 17, well my interpretation anyway

Interior coming on nicely Greg all the ingredients working really well together

Garry