Dion - I have a '72 donor car that is virtually rust free. I've been slicing off the handful of pieces that I'll need but feel free to contact me if you need any sheet metal parts that you can't find. It's got solid consoles on both sides.
I'd love to see it help a fellow Build-Off Challenger!
Keep up the great work!
Chris

Cut away the remainder of the sill panel.
Surface rust on the extra panel in front of heater tube.
No issues there. Will make patch panel for lead edge of the long that you
see just inside the wheel well.

Removed more of the door jamb except for brace area.
Cut open seatbelt anchor region to take care of that and prepare for
placing in new steel.
I removed the left half of inner firewall just before
tunnel overlap. The tunnel is sound from what I can tell on probing and
scraping. Test fit the new panel of firewall. Should be real nice when complete.
The bronze brazing mixture on those E brake tubes are a bugger. Did my best
not to destroy them.
I'm at the point now that I'll be sandblasting all these
areas. I'm awaiting a call from Lowes for my new
compressor (Christmas gift). Then that will be the next
coming weeks chore.

Pics

Pics

New firewall panel test-fit & de-brazed E-brake tubes.

I'm amazed at the level and extent of surgery you're taking on! Impressive.

I always thought R&R was short for "Rest and Relaxation", but your work has me thinking it's really "Remove and Repair"!

Keep up the great work.

Chris

ps. I should be able to get you that suspension console by around year end. Let me know if there are any other pieces you need.

Thanks for that Chris. I'm the one that gets slack jawed seeing the other builds.
The tube frames & carbon fiber stuff. Just incredible.
Hats off to all you guys.
Cheers all, Dion

Ok, I'm an idiot. I moved my post to the official challenge thread. Sorry.

Heheheh no worries Mike!

Since PA has been hit with the 20*F temps for a while now and
snow is on the ground. It's been slow progress. My kerosene heater
is having a hard time keeping up. I'm also waiting for my electrician
to be available to run a dedicated line for my new compressor.
So doing some other jobs.
Obtained some "past it" Fuchs to roll the car around for when
the weather breaks and commence with the sandblasting.
Also working on front struts. They are renewed and painted.
Proceeding with placing new bearings in the 911 hubs so I can
have the front suspension done and ready to bolt in.
Have some minor work to do on the six engine as well.
I'll update accordingly.
Cheers!

Bilsteins

The weather and electrician have conspired against Dion making progress. To my benefit as he helped me fish the wiring harness and hang the dash in my car yesterday. Thanks D! I guess it pays to have proper heat in the garage

Your Bilsteins are making me green with envy...

Our cold can't rival yours but we're in the 30s, which is uncomfortable enough.
I got a 220V electric heater and put in on a roll around stand. I just point at where I'm working and it makes all the difference.

Keep up the great work!

Tackling front suspension work. Replaced hub bearings and installed new
vented rotors.

Baked the hubs at 250*F for 25 minutes to coax the
races out.

Clean hubs

Repacked

New ball joints installed. Pay attention to the type of pinch bolt
you have. Torque slowly. Some have reported snapping but must have
"drawn" the bolt through with nut instead of hammering in flush first.

Rotors

Front calipers will be sent to PMB soon.
Time to get back to the chassis rust repair.

Nothing like a little brake and suspension porn on a Sunday evening!
Looking good, Dion.

Looks great,

great work; the bilsteins look very nice

Some garage time this afternoon.
Started prepping trunk area. Removed a chunk of JB weld from trunk I patched
years ago. Needless to say hole enlarged. Learned my lesson. So cut out around it.
This will get a patch.

Also some body filler escaped proper contouring from way back in 2004.
Popped it off to find a strange upward dent. No idea how
that would ever happen since it behind the rubber cap of bumper top.
So hammered it back to more appropriate shape.

Hammered.

Curious? Anyone have a "proper" hole on right side of rear of car near bumper mounts?
Looks like it's a mirror placement for tow eye bolt on left minus the tube and bracing.

Tow hook spot?

Yes. SOP

Mine has the same hole. No idea what it's for.

My replacement pan has that hole. I don't think it was on my 73.

Bodywork has come full stop for now.
Temps are in 20's to 30's and I've come down
with a major sinus infection. Uggh! Been battling it since New Years,it comes and go
but has come back with a vengeance. Being an RN we are the last
ones to see a doctor. Ok enough of that.
I'm updating with older pics here since it is my build thread. So it
serves as a great history.
So first is the 2.4 when I first purchased it nearly 2
years ago. I then cleaned it up and began replacing items

Took the carbs off for cleaning and replaced all the seals.

Found the ball that was supposed to be on the spring was missing.
Glad I dug into these Zeniths.
I found a great thread about the Zenith carb being rebuilt on the bird site:

http://forums.pelicanparts.com/porsche-911...by-project.html

I read it about 10 times before I had the nerve to dig in.

Replaced the alternator and painted the fan and shroud.

Shroud

Fan installed

So the upper valve covers that I did in silver paint were done over
in black since the silver didn't adhere very well. Must have had
remnants of oil on them. So after I adjusted the valves this past week
i cleaned the covers up again and did them in black.
Doing the valves with the motor out has to be the way to go.
If you have a lift. It took me over just 2 hours. First time doing a six.
I did it using the standard method as well as the "backside" method mentioned on the
bird site. I prefer the standard method honestly. As I found variations using the backside method. But that's me.

Put the carbs back on. Added the surrounding sheet metal.
Fan side will have to come back off to place motor mount on.
Momentarily felt bad as I had to cut into original 914/6 tin to
Make it fit the 2.4 engine. Oh well. Sorry purists!

Engine tin

Weather finally gave me a window to sandblast the left side of chassis.

Sandblasted

Cut out the firewall to make my life easier in the future.
I know there's plenty of opinions on this.
Rest assured it will be covered with a steel door made from another
firewall courtesy of Garold. I will be welding nuts to engines side to secure it. Add appropriate rubber seals,etc.
That's a way down the list. Nevertheless that's the plan

Nice work on the motor Dion,what history do you have on it ?,bet the can't wait to get it in.
You did a better job of the firewall cut than I did,mine was a bit of a hack job ,it was great to have it open to do timing etc.
I see you have the ''holy grail'' Bosch cast iron distributor ,is it a ''06'' off the "S" model ?.
Keep up the good work

Hey Dean, thanks for the compliments. I can't wait to be up and running like yours!
The distributor is a 0231-159-001 cast iron from a '67 T. I think they might also have
been used on the "S".
The 2.4 has an aluminum '67 case, counterweight crank, rods were checked and
balanced by Ray Litz. New Mahle pistons and cylinders.
Heads have 46 intake and 40 exhaust.
The Zeniths are configured similar to Webers and have the emission circuit eliminated.
The engine looks tired on the outside when I first purchased it. It was used for
about 20,000 miles in a VW Vanagon project for the fellow I Purchased it from.
He's a fellow 914 racer down in Texas. He was going to put it in his
vintage racer but decided to stay 4 cyl. He was happy in his class. Didn't want to deal with different specs and rules that the six would entail. Besides he has
a 356 project looming. Been on the phone and email a couple times with him.
Good guy. He's waiting for me to fire this thing up as well!

So it's sort of warming up here. Did a little but necessary project today.
Late start, wasn't in the mood to weld. Took care of the oil tank today.
Cleaned up, prepped, primered & painted. Prolly help Dave this week further
his. Hershey closing in.

Primer & paint.

Cool sounds like a nice engine with great mods,you will get good power with the carbs,the dizzy is from memory used on the "S" there were 3 types used over the years of that model which were all 2 litre motors 001, 003 and 006.
The dizzy you have has a fairly aggressive advance curve but was made to work with carbs however ,but the ''S'' had aggressive cams to suit,had a friend with one (68 ''S ") and he said the power came on late like an old 2 stroke motocrosser he said it was a very quick car on the open road.
Do you have stock cams?,what spec was the motor to start with?
I just guessing cause I'am the late stages of final tune with my zeniths but you would have 32mm vents,55-60 idles and mains around 130-135 or at least close,you will certainly have the setup to run the larger vents with your valve size.
Nice stock oil tank good score,mine has an PITA leak at the suction hose thread no matter how tight I do it up it leaks,only had it out 3 times so Iam fairly quick @ it now .
Keep up the good work on your car ok.

Dean, I wish I could say E cams but alas it's a T cam.
It started life with a magnesium case with hi-comp Forge-true Pistons with crank and rods from a 2.7.
It was a 2.5L essentially. Then it was rebuilt as the 2.4 with aluminum case.
with 2.7 crank & Rods, and then the 2.4 Mahle P&C with the Zeniths to suit.
Thanks for the info on Zeniths and distributor.
Keep at Dean I know you'll tame the oil leak!