From ‘72T to 2.5 S-R: GeLo Racing #44

[matteo68]

6. Internal Bosch battery cut-off switch:

I'm sure we've all seen pictures of STs and RSRs with the battery cut-off switch in the dashboard loudspeaker grille:



However it was always a mystery to me how the switch was actually mounted here given that there's a large hole in the shell for the loudspeaker itself. Then I found a load of pictures of the 17th S-R built (VIN 1155, originally sold to Karl-Heinz Feustel of Raceline in Switzerland and latterly sold by Axel Schuette in Germany in mid 2019 to the USA), including this one which reveals how they did it!



So once again we've tried to replicate this as best we can:



Looking at 1155 I think the mounting plate might need to be lowered a bit to get it to sit right but we will see...

[Mike]

5. Heinzmann external pull handle:

PM me your address so I can send the invoice for the use of my photograph.

[matteo68]

7. SWF washer bottle to oil breather bottle:

In an earlier post I described how we'd adapted an old SWF washer bottle into the breather bottle and located this in the front right corner of the engine bay, just as the factory did it for the 2.5 S-R and the RSR.

Brad Davis in the USA helpfully confirmed that the two brackets which the 356 battery strap is attached to are actually re-purposed oil scavenge pump line retaining brackets, of which one at least is still available:



So of course we cut off the ones we'd hand fabricated



and welded on a pair of these instead:



We were also puzzling about how the oil breather hoses were routed as most of the engine bay pictures I'd previously found didn't show this clearly but I found this one today - again from S-R 1155:



So we will be making another hole in the shoulder of the bottle for the short breather hose which would have otherwise gone to the airbox on a serial S (not possible with high butterfly trumpets obviously!) We'll plug one of the existing holes but leave the other one open - it all needs to breathe!

[matteo68]

5. Heinzmann external pull handle:

PM me your address so I can send the invoice for the use of my photograph.

Slip-up number 2 today... - now removed.

[stretch]

Great informative posts these past few days Matt. You can use my Heinzmann pictures free of charge !

[matteo68]

I'm done for a while on here Dave but the build will continue apace...

[stretch]

That's a shame. I would keep on posting if it was me. Watching with interest.

[Bootsy]

Ditto and 1,022,396 views to date says the same!- just PM’d you

[anglophone1]

Great stuff Matt, as ever - don’t let the neggos get you down- they aren’t doing anything anyway!
C

[anglophone1]

Great stuff Matt, as ever - don’t let the neggos get you down- they aren’t doing anything anyway!
C

[jeremyg]

I’d keep on Matt. Enjoying it. I wont be sending you an invoice for that advice.


Sent from my iPhone using Tapatalk

[Bootsy]

I wont be sending you an invoice for that

[hot66]

Great details Matt . Please keep posting and ignore Mike

[911hillclimber]

Said it before, just because you get few posts about the latest update does NOT mean people are negative or dis-interested.

My thread elsewhere on my Lola-Porsche hillclimb car is counting just over 1,389,000 hits, 3000 ish posts.
The number of posts diminishing over the last few years, the hit are still many.

I have found if you report on a difficult issue (or an interesting one like a full-on engine rebuild) then the replies increase as it is more interesting than a 'normal' report.

Keep it all coming!

[matteo68]

So we needed a twin CDI relay frame and, yes you can buy new ones from Restoration Design and Kroon:



But this isn't an exact copy of the original at all - the factory actually spot welded and joggled a piece of aluminium sheet onto a series relay frame (p/n 911.610.103.10) and then stripped and powder coated the whole thing in satin black:





so we're doing the same:




I had no idea what this metalworking technique known as joggle work was so had to look it up:

"Joggle work refers to a metalworking technique that involves creating a small offset or bend in a sheet of metal, allowing for a secure joint when connecting two pieces without increasing thickness. This process is commonly used in various industries, including aerospace and automotive, to ensure smooth overlaps and structural integrity."

In addition to all this, Joe at Greatworth also let in a strengthening rib into the extension section to match the one in the series frame - his fabrication skills are really very impressive.

Similarly we then assessed the spacing between the adjacent lower CDI box mounting holes either side of the join in the photos of the factory modded frame and drilled 3 holes in the extension to mirror those on the original.

More to follow next week.