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> What I did on semester break, Out of the classroom and into the garage
Dave-O
post Jan 2 2005, 11:20 PM
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Finally a chance to get in the garage and get my 914 ready for the next autocross season. This car is being built on a very tight budget. Many of the parts are being fabricated by myself. When i finish my homemade front anti-sway bar i will post a complete set of pictures of the build. In the meantime i made a lot of progress on other things. The first order of business was to groove and regrease all my badly creaking suspension bushings.


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Dave-O
post Jan 2 2005, 11:21 PM
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Next up, I installed the rear bar (kindly donated by a club member). I made up these brackets to instal It.


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Dave-O
post Jan 2 2005, 11:23 PM
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And in goes the bar. In this picture you can also see the repainted used koni reds i installed and the trailing arm i used to replace my old bent one.


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Dave-O
post Jan 2 2005, 11:26 PM
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Finally i got started on some interior projects. I first made a set of door panels out of 3/16" plywood. These pieces are actually lighter than the original paper-board and a much much more durable. I re-used the metal piece on the top of the old panel.


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Dave-O
post Jan 2 2005, 11:29 PM
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After upholstering, I hope the "waves" in the top folded part even out with time. My mistake was gluing the vinyl of this portion to the padding underneath. For future reference leave the padding "sit" inside the vinyl flap so it is not distorted by the pinched vinyl underneath. The handle is simply an overhead handle on a saturn parts car I have around. I covered the handle portion with vinyl and painted the end caps. These panels turned out much better than I expected, this was the first time I’ve done door panels.


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Dave-O
post Jan 2 2005, 11:31 PM
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crap, wrong picture. Here is the picture of the finished door panel.


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airsix
post Jan 2 2005, 11:32 PM
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Dave,
I'm interested to see your front sway-bar project. I love DIY stuff. Are you modifying a bar off of something else, or making up a new bar from scratch? If from scratch do you have plans for getting it heat treated and tempered to spring-temper?

-Ben M.
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Dave-O
post Jan 2 2005, 11:33 PM
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I also re-covered the dash face with a felt material. Since i eliminated the radio and glove box i had to make new backing panels out of aluminum sheet.


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Dave-O
post Jan 2 2005, 11:35 PM
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Here is the dash face installed. I still need to find a good knee pad. In this picture you can also see the 917-style shift knob...a christmas present from my dad (IMG:http://www.914world.com/bbs2/html/emoticons/smilie_pokal.gif)


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Dave-O
post Jan 2 2005, 11:36 PM
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I also picked up a set of these (IMG:http://www.914world.com/bbs2/html/emoticons/biggrin.gif)


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Dave-O
post Jan 2 2005, 11:42 PM
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QUOTE (airsix @ Jan 2 2005, 11:32 PM)
Dave,
I'm interested to see your front sway-bar project. I love DIY stuff. Are you modifying a bar off of something else, or making up a new bar from scratch? If from scratch do you have plans for getting it heat treated and tempered to spring-temper?

-Ben M.

well i guess i can let the cat out of the bag (IMG:http://www.914world.com/bbs2/html/emoticons/cool.gif) . I will be using a welt 22mm bar. I am making the rest of the hardware myself. This first picture is of the homemade bushing holder. I also made the backing plate and welded it into the car.


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Dave-O
post Jan 2 2005, 11:43 PM
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in the car


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Dave-O
post Jan 2 2005, 11:46 PM
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Here is the start of the adjustable "rod ends"


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Dave-O
post Jan 2 2005, 11:47 PM
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welded


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Dave-O
post Jan 2 2005, 11:48 PM
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I also finished making the adjustable rod connectors. This seemed like the easiest design to fabricate


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Dave-O
post Jan 2 2005, 11:50 PM
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i just got started making the attachment point when i had to go back to work. I'll do the rest over spring break,


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736conver
post Jan 3 2005, 12:35 AM
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Looks good Dave.
Hey are those my Konis in action there. I hope they were good.
As for your door panels you should glue the back side of the top. Just like the factory did. Or you can also staple them. I've done both and the both work well.
Did you put in a little foam cushion too?
If you do them over I have a staple gun and the small 4mm staples I could loan you.

Here's an example I did for a customer.


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736conver
post Jan 3 2005, 12:36 AM
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..


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Dave-O
post Jan 3 2005, 08:38 AM
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Brian, I glued the backside like the factory did. My problem was that i glued the pad that sits inside the top part down to the vinyl below (which is really uneven because it is pinched by those tabs). Then i glued the top piece of vinyl to the distorted pad. I'm going to try and work the vinyl loose from the pad below and as a last resort take the top apart again.

Yes, those are your old koni's. They seem to be working fine. I put a pair of your fronts in too. Thanks!

David
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736conver
post Jan 3 2005, 08:53 AM
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Glad the Koni's worked out. Give a call or email if you need anything else. I need to empty that trailer out.

Brian
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