Next, it was time to add these rings that help seal the exhaust as it enters the muffler. The only thing left is to add the tabs and springs to help hold things in place.

Chris, did you purchase the Boxster Trans mount, or build it?

Hi Stephen - It’s Renegade. I went with their LS and Boxster 6-speed kits. I’m a fan of “buy vs build, if it’s available...”
Though I did mod the front mount and added those spacers to move the whole drive train forward 1.5”.

Made a little tool / fixture to hold the spring tabs at the correct distance and angle. This is clamped to the exhaust tube and muffler then the tabs are welded on.

Then used that tool to install the tabs and complete the muffler install. Turned out pretty tidy.

Broke the warranty, would not expect anything less.

I like the tool, I would have just V banded them nice tight seal and done. What is the reasoning behind the springs? I never had much luck with them.

Stephen - It makes more sense when you see the whole install. With the muffler mounted to the trans, the whole engine/trans/exhaust is sorta one piece. There are v-bands at the junction of the headers and the exhaust tube. I actually got v-bands but decided on the spring approach to allow for a little movement, just in case.
I can always update to something else, if for some reason this doesn't work out.

.......watching your cool and skillfuf work may be tedious to you BUT it is addictive to us gearheads

Click to view attachment

Love seeing your progress, talent and passion.
Please tell me that hand formed Porsche Crest will be your hood ornament

Finally, something new: I got some of the parts finish coated.
The exhaust tubes and muffler mount have been ceramic coated. The shop that did it does mostly guns but is seeing more requests for exhausts.
The color is a nice titanium that has a sort of very light metal flake to it.

The parts look great and what a nice change from all the bare metal and rust!
This thing may turn out looking pretty cool after all...

Now that’s some wicked looking metal.
Very cool Chris!

Great looking coatings..... best part of the coatings is that the odds of you changing your mind/design are lessened.

[quote the odds of you changing your mind/design are lessened.
[/quote]

The looks really good Chris!

Well now you'll need to add a Lexan trunk floor to the Lexan firewall to show off those pretty pieces. At this rate, you might as well replace all the body sheet metal with acrylic so all these goodies can shine through!

Key word: "lessened"

Thanks to all for the compliments.

I'm really looking forward to getting the entire chassis blasted and in one color, even if it's primer. Seeing other builds move into that state makes me think my car will suddenly feel much closer to being, um, well... Let's go with "complete" running. I don't ever seeing it being "done".

Today's progress: Started on the plasma table.

The part needs to be stepped up in the middle and I was able to find what turned out to be the perfect press set up. What are the odds?

Carefully set the piece in the press with the appropriate sized "helper" pieces.

The press is a beast and makes quick work of this sort of thing.

I couldn't resist adding some additional strength and style points.

Very creative there!

Weld on the nuts...

And, it's in!

Reservoir in place. I like the way it turned out.

^strange place to have your bottle opener

That 16ga? What kind of press do you have? Piece looks great!

Thanks Andrew!
I used 18 ga. The press is the one that was sitting next to the bender we used on your cage bars. The pump that powers the bender has dry break connectors that also hook to the press so in about 10 seconds, I have a giant powered press!

Let me know if you need anything squashed!

I have sheers/presses at my disposal from the people that make our frames.

They sheer 1/8" stock with it and the things 15ft tall and 20 tons! Apparently it has 3' thick concrete underneath it.



I just know how big those machines can be which is why I asked as I didn't remember seeing one at your shop!

That Fab piece is awesome I'm sure that press is going to come in handy very soon for some of the trick stuff. If YOU want anything heavier duty pressed or sheered let me know.

See you been spying on my thread again I like the mount why did you choose that location? I am just wondering, as I put mine closer to the stock area, so the over filled fluid can run done the fresh paint and start the 914 conversion to rust process all over again.

Start working on the solid roof section I have my ideas in my head as to how to do it, just would prefer you to burn the stack of metal that comes from doing the work 3-6 times to get it just right.

Stephen - I located it there because the chassis stiffening bars I ran to the front shock towers sort of prevent me using the space where the stock reservoir lived.
The roof will likely not start to happen until after I have it on the road. I want to focus on getting it running.

Next, it was time to make a panel to close off where the late model cars mount the fuel pump. I'll use this as the passage for the reservoir hoses to the pedal assembly.

I started off by cutting a simple panel with the appropriate holes for the hoses.

A few grommets and I'm done...

That looked OK but I figured I could do better so decided to make a die for the press that would allow me to raise the section around the hose holes.

I plasma cut a couple pieces of 10 ga and marked them so I could align everything once it was all in the press.

Into the press and out comes a tidy little part!
And yes, I installed the grommets AFTER pressing...

A couple more items checked off the to-do list.

Chris a question for you, are you clamping the sheet before pressing like you would if you where hammer forming? Just wondering how your get a nice finished part. Or is it a bit rough and the run it through a planning hammer or lots of hammer and dolly work. Wheel them, just wondering wanting to learn a bit.

Stephen - I measure and mark the panel so I know how to position it over the "open" lower die. Then I set that "insert" piece on top of the panel, doing my best to align those cross marks, and then press it, forcing that insert down into the panel, creating the raised section. The press does all the stretching and flattens the part all at the same time. No secondary operations needed.

I figured someone might be interested so... here's the video of the part being made.


https://www.youtube.com/watch?v=G16Q0V4LXww


And @Andyrew , there's a good look at the press you were asking about.

Nice! I remember that being there. It's able to do anlog more than I thought it would!!

Sharpie transfer punch, a few holes, find some suitable screws and it's all done.

Then moved on to making a new plate to mount the in-tank fuel pump. This will get welded to the tank in place of the filler, which will be relocated.
Using the plasma table really does feel like cheating.

It'll go about here. I'll be ordering a new tank, too.

Nice Chris-

If using a plasma table makes you a feel like a cheater, I'm like Kent. A repeat offender relying on some of my shop talent when pressed. Your creativity is mind blowing. Love this thread.

Oscar

@76-914

Oscar -
You are too kind... Thanks for the generous compliment.

More panel fab. This time, its the piece that'll serve as the front bulkhead for the fuel lines.
I'm figuring out better processes for pressing the raised sections:
I cut the female piece sized exactly the same as the panel. Then I just sharpied where the male piece needs to sit. Much simpler to set up and virtually guarantees a great result.

PRESS and...
Presto! (see what I did there? )

Turned out nicely.

Next, it's time to fit the fittings to see how they fit. Hoping they won't give me fits.... wait, what?

Just set in place to see what's what. The panel will sit a bit higher once it's bolted in, but you get the idea.

And the tank side. It'll be soft lines from here up to the pump. One supply, one return.

Okay I got it, the picture left out one detail, the upper upper die, or that flat piece that sets onto of the 10ga plate that presses down.

I like the setup here, and the bulk head for the fuel lines. Same general setup going inlace at the back of the cabin?

And if you think a plasma table is cheating then keep right on doing it, as the end product is worth the "cheat".

"Tunnel Vision"

The stiffening plate at the front is 10 ga - thick enough to support threads. So a quick mark/drill/tap and the bulkhead is finished.