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> Wallys914/8 Conversion and Restoration, The Build Up Continues, and Continues, and Continues
Lavanaut
post Dec 4 2008, 11:08 AM
Post #21


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Damn, it must be fun to have these kinds of skills in your arsenal. Keep up the work, I can't wait to see how this thing turns out. Oh and thank you for multiple pics per post...much easier to read that way. (IMG:style_emoticons/default/wink.gif)

Reid
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jaybird840
post Dec 5 2008, 10:51 PM
Post #22


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Welcome to the world of the 2.7! I'm about six months into a rebuild of a 2.7 (weekend warrior). If you don't have much experience with these motors, a lot of the conventional stuff you know about motor rebuilding doesn't apply. Find a copy of Wayne Dempsey's book "how to rebuild and modify Porsche 911 engines" and read it about a dozen times. You'll go nutz deep on the rebuild, and if you don't have the case properly prepped (case savers, etc) you'll flush several grand. The magnesium cases are notoriously soft (ask me how I know...I just pulled a stud out of the case bolting the oil pump in yesterday). For your machine work, find CGarr on the Pelican board. He did my heads and case for not much $$ and his work is top notch. I could write for days on stuff to watch out for. Spend some time on the Pelican site in the 911 engine rebuilding forum and you'll learn a ton quickly. Here's the link to my 2.7RS spec motor build.....
http://forums.pelicanparts.com/showthread.php?t=407637

Keep up the great work!!!!

--Jaybird
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wallys914
post Dec 25 2008, 01:03 AM
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So it has been a few weeks since I updated this post, so far the passenger motor mount has been removed and the holes and have been filled. I got my trans, from a fellow worlder, for 300 with shift linkage and this last week has been spent setting up the cage and getting a tube bender.


In the mean time I cleaned and painted my new 11 blade fan.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i328.photobucket.com-9631-1294444661.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i328.photobucket.com-9631-1294444662.2.jpg)

Dont have a white board use a hood...

(IMG:http://www.914world.com/bbs2/uploads_offsite/i328.photobucket.com-9631-1294444663.3.jpg)

Trans...Supposedly rebuilt we will see...

(IMG:http://www.914world.com/bbs2/uploads_offsite/i328.photobucket.com-9631-1294444663.4.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i328.photobucket.com-9631-1294444664.5.jpg)
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wallys914
post Dec 25 2008, 01:04 AM
Post #24


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So after the cleaning and the welding time to get creative.

Cage started...

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration122416.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration122418.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration122420.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration122423.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration122424.jpg)

Got the tube bender which works well....

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration122427.jpg)


So where i stand today is i have the main hoop bent and all the footprints for the cage welded in, this weekend will be the getting the new engine shelf in, welding, in the hoop and the rest of the cage will be bent and welded in. Got some early Christmas presents.

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration122428.jpg)
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FourBlades
post Dec 25 2008, 11:33 AM
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I love this thread! Great work. Your welding is really awesome.

Can you show some pictures of bending tubes and how you make your
roll cage???

Thanks...John
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J P Stein
post Dec 25 2008, 11:49 AM
Post #26


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In no particular order:
There are better rust conversion products available than POR-15. Rust Mort is one.
Light colors for the engine room and trunks make for better vision & inspection.
Doublers for a cage should (IMO) wrap down around to the side of the longs.....bout 3/16 thick also.
The bar you've put in twixt the towers is usless unless you plan to remove the trunk sheet metal...not a good idea in a sreet car.
If you feel the need to weld, all the seams from the fire wall back to the trans mount cry out for it.....same up front. All that caulking does is hide rust/seam failures.
The suspension ears can use this treatment also.....but you seem to have other problems in that area.
Straight & 90 deg air powered die grinders are a boon to body work of all kinds.
There are a multitude of attachments from carbide rotory cutters to scotchbrite style discs for all kinds of metal prep.....and everything in between.
I'll do some pix if you wanna see how they work. I have a wire wheel or 2......somewhere...good for removing seam sealer.

A pic


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J P Stein
post Dec 25 2008, 11:52 AM
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Another. There are a lot more where these came from.


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J P Stein
post Dec 25 2008, 12:04 PM
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You may find this thread interesting.

http://forums.pelicanparts.com/showthread.php?t=199326
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wallys914
post Dec 25 2008, 12:05 PM
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QUOTE(J P Stein @ Dec 25 2008, 09:52 AM) *

Another. There are a lot more where these came from.


Thank you, and i will get some more pics of the cage making process it will continue tomorrow evening, santa dumped a new clutch kit today and some other ish....

Thanks Again Guys
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J P Stein
post Dec 25 2008, 12:23 PM
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A drill press, vice, & hole saws are good for the fishmouth cuts needed for a cage.
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wallys914
post Dec 25 2008, 11:33 PM
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so today I got some work done on the cage, i got the upper door bar bent and the rest of the cages footprints welded down with the wifeys help.

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration003-13.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration006-14.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration007-13.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration008-14.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration009-12.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration010-10.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration014-11.jpg)

I had this extra piece maybe i can make a cow pushing bumper, well wait it would only hit their knees....

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration015-11.jpg)

Well tomorrow after work I will get this all welded in... Wish me luck!
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LarryR
post Dec 26 2008, 12:07 AM
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Nice bending work. However I think I would get another piece of tubing and push that rear hoop a lot higher. You want it as far away from your head as possible and it looks like you left about 3" on the table...

Very nice progress. (IMG:style_emoticons/default/beerchug.gif)
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LarryR
post Dec 26 2008, 12:16 AM
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Here is a pic of a 914 cage by one of the best in the bay area TC Design:
Attached Image
Note how much further up the cage is. Mine was done by them and the top will still go on even with the bars up there.

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wallys914
post Dec 26 2008, 12:40 AM
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Well it is up about 4 inchs from the top of the seat, and it is going back under the sail about 2 inches, so far enough back and up that it is out of my way even with a helmet on, Im big, but not that big (Tall, No Offense to big fat guys, I'm one too (IMG:style_emoticons/default/smile.gif) ). Plus I still want to have the full interior, I believe it will pass SCCA tech, I hope in case someday I want to take it on the track.

Thank you for the pic and the advice though.
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J P Stein
post Dec 26 2008, 07:03 AM
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Go to the SCCA website and read the rules on helmet clearance to the top of the cage.....otherwise known as the broomstick rule.
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wallys914
post Dec 26 2008, 03:01 PM
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So you're all right, it should be about 2-3 inches taller. Now can i add that to the bottom if the pieces are sleeved together? reading this form the SCCA rules it looks like it. Let me know if any one knows for sure.


Appendix G. 2007 Roll Cage Rules
General
The following procedures are approved for modification to roll bars/cages
that do not meet the two (2) inch required minimum: The old main hoop
may be cut off near the chassis mounting and a new main hoop of equal
tube size or a section of equal tubing size may be added, and inner tube(s)
must be used to mate all sections together. All braces must be minimum
distance from top of hoop per Section 9.4. All welding for this modification
must be arc welded (min.). The inner tube(s) must be rosette welded
three (3) places near top and bottom, see figure 21.


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J P Stein
post Dec 26 2008, 06:03 PM
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QUOTE(wallys914 @ Dec 26 2008, 01:01 PM) *

So you're all right, it should be about 2-3 inches taller.


Why of course we're right.....we are 914 internet exspurts. (IMG:style_emoticons/default/biggrin.gif)

Do it "by the book".
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wallys914
post Dec 27 2008, 03:04 PM
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So Last night, I added 2 1/2 inches to the main hoop by sleeving it. (IMG:style_emoticons/default/smilie_pokal.gif)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration005-14.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration003-14.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration012-15.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration013-16.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration011-13.jpg)

And today I started to notch the door bars. We will see what I get wrong on those....
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wallys914
post Dec 28 2008, 08:49 PM
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Door Bars got bent and got tacked in today, Progress is Great, would have finished the front crossbar but ran out of straight tube.... tomorrow i will pick up some more and git-er-dun! (IMG:style_emoticons/default/type.gif)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration001-11.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration003-15.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration004-15.jpg)
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wallys914
post Jan 3 2009, 01:46 PM
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Got the last piece of the halo in,

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration001-12.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration003-16.jpg)

Seems kind of far back i know, but i couldnt get the latches for the roof to work other wise.....

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration005-15.jpg)

So back it has to go, but looking at some other cages it seems to be the norm if running all stock interior.

Last one....

(IMG:http://i328.photobucket.com/albums/l326/walloch/PorscheRestoration008-15.jpg)

and I got the top of the Halo Tacked in, the door bars are bent, fit, and tacked in, Finishing up the X in the trunk, and then the complete welding starts tomorrow along with triangulation of the rear hoop, and gusseting.

(IMG:http://i328.photobucket.com/albums/l326/walloch/photobucketcom010.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/photobucketcom009.jpg)

(IMG:http://i328.photobucket.com/albums/l326/walloch/photobucketcom007.jpg)
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