Our 911 build thread (now pic heavy 56k no-no)

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crisc204
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Our 911 build thread (now pic heavy 56k no-no)

Post by crisc204 »

Hi all,
My name is Cris.
I have worked in the motor-trade for 15 years at my family business which is a body-shop.
We work solely within the Porsche marque and as such have built up quite a customer base from trade and private customers due to a real passion for the Porsche marque in my case particularly the 911 RS light-weight.

I don't mind admitting I have got it real bad... the RS is the car I wanted since my school days and it was already 20 years old then!!

So I would like to share my experience re-building my 911. Its been several years in the making and is now around 80% done, this should be the final year of the build and I may even get to drive the car at some point soon...

Sorry to disappoint, but the rocketing value of Lightweights meant that I had to start with its budget little brother and build my car rather than buy one outright.

We have now entered the fun stage of putting it all back together.

Getting to this point has taken far longer than anticipated and I have come close to selling the car on a few occasions but now the target is firmly in the cross-hairs I have found a new drive to get it done.

Right here's the car when we got to the workshop,

Image

It looks very different now and has undergone countless hours of prep and to get it to the level that I want.

First it was stripped of all components.

Then the shell was taken back to bare metal to see what I had actually bought.
It was actually very good! Not that much of a surprise as I went through every part of the car, crawling about underneath it in the rain...

This car had been very well cared for and showed signs of a rebuilt Engine and box and it also had complete new Stainless exhaust, quickshift
and had been retrimmed generally pampered!

All the interior was stored and the Engine and gearbox sold as it was always going to have either a modified 3.2 carrera engine or a 3.6 powerplant if finances allowed the full on build I had in mind.

I would love to show you the first stages of stripping the car down and removing the paint and sealer however to put it bluntly some little oick stole my camera a while back and I lost about 100 prep images. :(
(btw I stopped counting the hrs at 400 lol)

I have the latter half of the build across about 50 pics,
finding things like the build number still on the dash and doors made me quite a happy nerd :lol:

Image

After getting through lots of oxy-acetyl, wire brushes and dual-action sander D/A disks I had a bare metal shell which did not actualy need much to make a very nice car, this would of course been tooooo easy.

so a silly plan was hatched alongside a sensible one with way-points with regard to financing the build.

1. A very faithful RS recreation with 3.2 power.

2. Bonkers wide body RSR recreation with 3.6 power.

At some point I would have to choose which but lots of jobs were common to both such as strenghtening the shell and as a matter of course for a 26 year old car some things would have to be checked as It's meant to be a keeper.

this is what greets me when I open the doors at work....

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So i've given the game away early... I'll add more of the build later its all uploading now...
Last edited by crisc204 on Wed Mar 03, 2010 11:33 pm, edited 3 times in total.
sladey
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Post by sladey »

Welcome Cris - keep the pics coming
The simple things you see are all complicated
I look pretty young but I'm just backdated yeah
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Post by Mitch »

Cris, looks nice even before you started so looking forward to seeing some more...
BTW, is that Minerva Blue? Always liked that.
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Post by theorangeperil »

Welcome Chris. Love the colour! 8)
Where are you based in West London?
Peter
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Post by crisc204 »

Thanks guys, I have added more above in post #1.

It is or was indeed Minerva blue 304, still is my favorite Porsche colour.
I bought this car after seeing a 1" ad in the Autotrader, it was my Birthday and the car was my favorite colour... meant to be perhaps.

My Pops used to be involved in running several race cars in that colour many years ago in the Porsche cup/ you were a fully fledged race team if you had a van and a trailer back then...
I'll find some old pics...

Finally I'm from Ealing way but outside office hours can often be found in the wild's of Leicester as I'm still trying to import my Northern bird... :wink:
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911 build

Post by crisc204 »

So we took a couple of bits off....

Image

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We found very little wrong with the car out of the ordinary, there was some surface corrosion where the rear 1/4 light windows had not been sealing and that was about it!

So a 'while' later I have a bare metal shell, with a primer wash over it to keep it from oxidising whist work continues.
(a 'While' does not cover it.)

About now it becomes very handy to have a Jig. Ours pictured below today (not my car btw) was made by Car Bench which several years ago was the Porsche approved chassis repair system, they now favour Celete, I could tell you the rumour why but it will get me in bother ;) lol

Image

At this point I had still not decided if the car would be an RS or RSR but either way it needed to go on the Jig to make sure it was straight and true due to 20+ years of driving, wear and tear... plus we decided to replace the inner and outer sills because the O/s was showing signs corrosion on one of the kidney panels + outer sill and also it was expected the car would need them.

This is major stuctural work and on a jig is imho the only way to do it.

In the end the inner and outer sills were replaced along with fitting new kidney panels both sides. This work would have been covered in detail but due to the theft of the camera we only have a couple of pics of this stage..

100 odd hours later....

Image

By now as you can see I had decided on the bodyshell style if not the power-plant, this is the car on Jig2 after new inner and outer sills kidney panels and a few other bits n' bobs

Including fitting RS spec wing extensions, remember my car was a slim bodied impact bumper model. Well, pops rolled up the sleeves and got stuck in and made some using SC flairs as a base.

couple of pics below showing the rear wings

Image

Image

The car was now almost ready for primer but I formed the opinion that a true lightweight recreation should not have a sunroof...
out came the tools and no more sunroof, this is not easy!
2 or 3 pics and a couple of lines explanation do not adequately explain whats involved to do it properly and make it look factory...

Image

Image

sorry about above iirc a phone pic..

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also added the early front panel and RS & S twin battery boxes as my car is non-servo its starting to look pretty close. cleaned off the front cross-member and inner wings, along the tops of the front inner wing
needed some love sorry no pics of that.

The only unexpected job was a repair inside the torque tube.

this area shown below taped up... can also see the new kidney panel.

Image

The mounting faces for the spring plate bushes had rusted away so had these made at a local machine shop... had a job lot made

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and installed them the notch at the bottom lets out moisture same as factory ...

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This brings us up to the shell being ready for primer!!! yay

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had to buy a pair of these boooooo, that was painful!!!!!

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more to come feedback welcomed!!

oh during this stage this car below came in for a repaint... Real deal RS. my decisions up to this point were choices after building this one up and driving it I had to have one!!


Image
Cris
Last edited by crisc204 on Thu Mar 04, 2010 12:36 am, edited 1 time in total.
210bhp
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Post by 210bhp »

Cris

If that RS is in it's original colour it is the only one in the world. Jade Green. Used to belong to Mark Waring but I thought he sold it abroad.
It is a touring not a lightweight.
Looks like there is a serious problem with the front windscreen pillar :lol:
Regards
Mike
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Post by crisc204 »

got a bit carried away with the swirly button on photobucket will fix in a min.

should have been a white RS with green decals :? leaving this up as its still pretty and i'll edit above! I have about 1200 images of Porsche's we have worked on, thats the wrong pic :oops: I'm much better with tools than pic links lol

edit:

Should add that Green RS shown is an old pic, 3-3.5 years ago not 100% sure but I know who owned it then and its was not Mr Waring.
Also just for info I wouldn't comment on its whereabouts, however vague, or that of any other car/owner which uses our workshop. The cars while on site and shiney are shown for everyones enjoyment.

simply put, its just on because its pretty...
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Post by Roddavies »

Hi Cris, Looking at thse doors I was only feet from you when I tried to find your workshop - very discreet ;) Surprised you didn't hear me burbling away outside!

I"m now subscribed and look foward to seeing progress as it continues. I'll come and see you in the next couple of weeks and discuss my next 914 plans:)

All the best, Rod.
crisc204
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Post by crisc204 »

Hi, Rod
I'll be adding more in the week when I can find a spare hour, we are building 2 cars with dead-lines fast approaching!

Your welcome to drop by the workshop when your next Wembley with our neighbours don't forget to have a look on the Wembley-stadium event website though as things tend to get very busy on big event days, we tend to plan things around them.

With all the airtools & hammers ect you can not always hear whats going on outside.

Jaz are building a rather nice full on RSR rep aswell, I'll introduce you to Steve Jaz's bossman aswell

See you when you get here...
Cris
crisc204
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Post by crisc204 »

Shocking!

Sorry, I've not posted anything since March 6!

Well the rear suspension is now on with either new or recon goodies...

3.2 Rear Aluminium arms with new bushes.

Neatrix (sp) spring plate bushes.

Spring plates were very good so got them zinc plated (yellow) not right for an RS but Porsche o.e. They are £640 a pair new....

Bilstein dampers. (stiffer)

Thicker Torsions bars.

3.2 brakes, these are a stopgap.
I really wanted to fit turbo brakes but a couple of people who we know that raced 911's past and present said they would be overkill for the cars useage and current spec. When I get to the evolution planned in 2012 I'll come back to this.

Found a Porsche quick shift in the work stores and fitted new bushes ect, really would like a wevo shifter but it will have to wait for a while.
I'm not certain if the quick-shift is for me as the 915 is a slow box compared with what I'm used to but we'll see.

Also now have a rebuilt "big-tooth" 915 gearbox ready to go in, the one with the Oil cooler on the side, Also quite like the idea of the race style extra oil feed sytem which is almost certain to appear soon ;)

Also have a 3.0 SC engine which is ready to fit and may even be fitted if no-one makes an offer on it through the classifieds.
I'm quite open on that matter. It will provide enough BHP etc how-ever since I drove a certain standard albeit blueprinted 3.2 powered Black and Silver SSE we built.
I now have a hunch a 3.2 with some trickery on the intakes and exhaust will be more "me" than the 3.0 or 3.6 engines in stock

(more to add)

That said a blueprinted SC is no slouch (imho)

We have been looking into Jenvey throttle bodies and standalone management and hopefully twin plug heads, i would like my little project to 'drive' and respond much like a modern car and make good power.
While retaining as many group parts as poss.

Bottom line a factory 'hotrod' built from the lwb 70-89 parts bin putting a 993 3.6 engine in the car now almost feels like cheating...

More as I bolt it together
ta
Cris
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Post by buzz808 »

210bhp this could be the car you were thinking about,as far as we could tell it was original colour and down here with us in New Zealand,i will try and find out more info on this car it was only in for small amount of paint
Image
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Post by Vic Cohen »

Surprised u ever found time to do any proper work..........................believe me the 3.2 ,steel callipers, with silicon fluid and appropriate brake pipes will be plenty enough even with ur big feet ..................................done track days in the Outsapn never a prob ..................remember i had the 917 /TURBO brakes on the 3 0 rs , were great of course but overkill IMO
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Post by crisc204 »

Hi Alex,

When Mike (210bhp) refers to the car as being the only Jade Green car in the world I believe he means the only factory right hand drive Jade Green RS. I dont have "the RS book" atm to check, lent it to a friend, but iirc thats gist of it.

I have seen one or two left hand drive Jade Green RS about like your Kiwi one in the pic, one at the classics at the castle show here in the UK a couple of weeks ago with French number plates (tags, id plates)

Since then the RHD one we painted has turned up on here! its a small world

VC

I know your all right about the 3.2 brakes, Rob W, Steve, yourself, Graeme L and pops all say the same all have bundles of track time and years on the 911's ...but have you even met a son who will straight away admit his dad was right? :lol:
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