DDK - Die Deutschen Klassiker

What a shell!
It is hard just to rebuild these cars, but to chase all this detail adds so much effort, but max satisfaction.
Very nice thread, thanks for the regular posts.

Thanks chaps.

We're also leaving the holes down the centre of the floor unfilled / no grommets - Export 56 left these open on 1195 as you can see in my previous post:

Matt, just caught up on this thread - excellent work

Drain holes all welded up...


And more fettling of the rear arches to achieve the super smooth profile we want:

Oh those arches look good

In addition to the twin CDI frame we made before Christmas, we also needed a twin coil console which was mounted on the front crossmember in the engine bay:



The competition execution (shell scope) for the 911 S (sheet lists this as "Konsole für Zundspulen" with part number 911.610.900.00. However this actually comprised two parts:
i) the console itself (Qty: 1) with part number 911.610.901.00 and
ii) Schweißmutter M8 DIN 29" - Weld nut M8, (Qty: 3) with part number 900.260.006.00:


The sheet also confirms for the avoidance of doubt that the console goes on the crossmember.

After obtaining a couple of less than satisfactory repro consoles elsewhere (AASE being one) - an original one being nigh on impossible to find -
Jimmy Tidwell (JimmyT on ESR) in the USA confirmed he had the CAD drawings to make one, although he'd never done so before as he didn't think there was any demand for them.
However Jimmy's previous work (making a pair of centre lube camshaft oil line adapters for me for the chain housing covers) was excellent so I was confident this would be of similar quality:



The console was designed with three sides only as it would not be possible to weld the rear side onto the crossmember at the base of it so the rear is left open.

The factory M8 weld nuts look like this:

The distinctive features are the 3 radial spokes that are electrically welded to the backside of the bracket and the central top ring that positions the nut in the body’s hole. In this case, the pilot is thinner than the metal thickness, so there is a sunken ring surrounding the threads.

Jimmy also supplied a cross-section drawing of the console for information:


6 weeks later and the console was done and shipped to me prior to any payment being requested ($29.64) as he wanted me to be happy with it first:



Needless to say of course I was - especially when I saw the laser-etched part number on the underside, the high quality stainless steel material, his super-neat welding and the 3 supplied M8 screws to affix the twin coil bracket (which I already have) onto the console with.

So another part sourced and ready to go on now...

Love the attention to detail. Superb.

This is going to be a superlative car

More fettling of those awesome arches...

Looking forward to seeing this during a visit next week Matt. Looking good.

Looking superb Matt

Arches all finished last week...

Rear anti-roll bar brackets fitted now.

Note the strengthening plates we welded to the inner faces of the brackets as the serial S brackets are relatively weak being pressed steel - we have seen significantly more robust aftermarket brackets from Elephant Racing and different strengthening plates fitted in this area but these were not factory spec.



Note the standard spec ARB brackets circled in red as fitted by Porsche Classic during the restoration of 0538:



Elephant Racing brackets by contrast:


And crude, but no doubt equally effective, fabricated strengthening plates on 0495:

The elephant racing ones are good - mine have been on for maybe 20 years - knocked the ok type off a couple of times

These arrived earlier this week - aluminium calipers, as fitted to the 911R - part numbers 901.351.057.20 (front, left) and 901.351.058.20 (front, right), originally supplied by the factory with Ferodo DS11 brake pads:



Fabio Paneque, General Manager at PMB Performance confirms they were also fitted to to the rear axle on 2.3 and 2.5 STs / SRs and that they are even rarer than the magnesium 908-type quick release calipers sometimes fitted to the front axle on STs. Dave Pateman on ESR, a bit of an acknowledged Porsche brake expert, also confirmed they are the least known of all Porsche calipers. Here is an original alu caliper fitted to the ex-AAW / Antti Wihurti 2.3 ST 911 030 1014:



This pair was the last of ten authentic repro sets made by Ate for Michael Roock of Roock Sportsystem in Germany, previous owner and restorer of genuine 2.5 SRs 911 230 0908 (Danal Oldenkott / Clemens Schickentanz) and 911 230 0909 (Peter Zbinden / 1972 Swiss Touring Car Champion).

The calipers have a 38mm diameter piston and take standard pads.

We shall be using these instead of the refurbished steel 'M' type calipers supplied by PMB along with PMB-refurbished alu S front calipers.