Glad to help stoke the motivation! Let me know if you need to see it again. I am roughly 30 min from you. Gives me some test drivetime while I work through my worn out suspension issues. BTW your car looks great.
Rich

(taking copious bumper cutout notes...) Natural for us Arizona peops to have a wee drop in motivation over the summer.... Your work looks great.

Here's this afternoon's diversion...
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That's a nice touch on the gas cap...is it a kit or your design?

I just looked at the pics of this kit and made my own.

https://www.thoro-tec.de/en/p/fuel-cap-porsche-914

Can't see spending $400 for it

I have a couple ideas on the trim ring, but believe it may not be "needed"

Did some more work on the front bumper opening this afternoon. Cleaned up the edge with the angle grinder and did a test fit to double check the opening I had drawn out.
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I cut out the inlet to match the opening on the bumper.
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May not really be needed, but more air flow in PHX is always a good idea! I hit the edges with some leftover back spray paint, and mounted it up again.
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Looks like it will work well enough...

Love the enlarged opening.....

Kevin, mine's a '74 so it has the curved brace on the inside of the frunk. I cut just below where the brace is spot welded to the front of the chassis. I can't recall what year your 914 is, so whether you have that bracing or not kind of dictates where you can cut...

Mike

Your car looks spectacular, very cool to have another Subie powered 914 in the area. Rich swung by my house on Friday after he left yours, his was looking great also. Let me know if you need anything.
Ed

Still a bit of work needed, but I'm making progress...I think!
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Looks great

Let me know if you need some pics of the radiator support frame.
Ed @mowag4 is a huge local resource too. Big HP Subie builds.

Rich

Getting there...
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Far from perfect, but good enough...at least for now!
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Inlet/opening came out ok.
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Thinking I may eventually spray the bumpers with the Raptor liner to match the rockers. Would also hide more of my imperfect repairs!

Looking great! I’m on a forced hiatus my EZ30R swap because of work. But this Spring, I got big plans, big plans!

looks really good Mike... Cutout is very nicely done and I like the filled in bumper holes too... (PS Mine's a 74 as well)

Got it sprayed with rattle can satin black. Decent, but needs more work with some high-build and the sanding block to better hide the imperfections.
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Now on to the rear bumper But it will have to wait; most of my weekend has been spent with this guy up at WestWorld playing photographer, groom, water boy, etc. but he's so worth it!
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This is her last show with Sudden Impact AKA Clint. Makes us all more than a little

I got the rear bumper cleaned up, painted, and mounted. It was a lot rougher than the front.
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I still need to figure out how to fill in that missing chunk in the bumper top

Then I moved on to cutting out and patching the vent/grille on the cowl. I kept trying to figure out how I would handle water getting in the vent and decided the "easiest" thing to do was just remove it.
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Backing the welds with copper really helps, but clamping/holding the copper in place is quite the challenge!

Quite the tedious process, but came out ok.
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Tomorrow I'll see how level I got the filler when I start sanding
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Got it all flat, then filled with glazing putty, then finally all sanded out with 120, then 180, then 320...
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Just waiting for primer to show up

Looking good Mike... Top notch work as usual. I forget what you'd described as your long-term plans for heating/cooling. I know you've finished the block-off plates, etc.

Kevin

Kevin, my plan is to just have heated seats. We'll see if that plan fly's...or if it fly's like the Spruce Goose!

I've been working on my radiator mount/frame. But I had to replace my phone and the pics I took are in the new iPhone format and basically unusable. And, I got the whole thing welded together only to discover it was about 1/8" too tall/high. Had to cut off the bottom mounts, move them down, then re-do the upper braces (why there's 4 Rivnuts instead of 2 on each upper brace.


So, I gave up and deleted what I'd taken, but took some new ones this afternoon while testing to see with my rather sophisticated CAD system if I can mount the aluminum shrouding before installing the radiator mount...State of the art CAD system! Even my scissors suck...
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Survey says...Nope! Can't mount the lower sides before it's installed in the car.
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Once it's in the car I believe things will fit ok.
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Need an extra 1/2" or so on the back of the bottom shroud to close up this gap though!
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Arguing with myself over how to shroud the portion above the curved bracing. Not sure if I should go angled like this, and then a cosmetic cover over the top, or...
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Looks great Mike... Your CAD system is primo and a notch better than my own .. My only regret (thus far) with my rad mount is that I didn't leave sufficient room for rubber isolaters. I squeezed in some lame thin pads, but I wish I'd have planned for a real buffer of some sorts.... Just FYI...

Looks really good! I’m following build closely since I’m planning to do something very similar.

Couple of questions…. 1. When you ran the coolant hoses in the longs, did you run them right inside of the existing insulated ducts?
2. Is the part number of the radiator “MMRAD-CEL-00”?
3. What radiator fans are you using?

Thanks, Aaron

“MMRAD-CEL-00”

Would make sense. MishiMoto Radiator Celica 2000-2004.

There are cheaper copies of the 'racing' radiator for the Celica/MR-S than Mishimoto. Using the Celica radiator is well documented here. I used the factory Celica fans as the generic Chinese fans are questionable. I also used the MR-S version of this radiator as the hose inlets are in a better place.

No ducts in my longs. Completely open/empty longs. Couple pics here:
http://www.914world.com/bbs2/index.php?s=&...t&p=2800284

It's a 2000-2005 Toyota Celica radiator. Mishimoto makes nice things. Didn't want to buy a Chinese knock off radiator, so I waited till they had it on sale around black Friday for about $215.

I have not purchased fans or shroud yet. Debating what fans to go with, etc.

Waiting on some aluminum sheet to get here for the shroud/ducting for the radiator. Meanwhile, my toolbox and stuff kept getting wet when it rained despite my temporary cover. With more rain due soon I decided to build a more permanent cover to try and keep things dry & protected.

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Simple and hopefully effective...

This should keep things dry.
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One sheet of aluminum showed up, so I tried to do what I could with it! Still waiting on the second sheet to make it here...
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I had a gift card for HF so I picked up this cheap "metal bender". As usual for HF, required a bit of modification to work half decent...
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I lost a bit of width, but the top piece cant move around anymore! I thought about drilling a couple more sets of holes across it at maybe 8" & 12", but I think just getting a couple more larger C clamps would be quicker/easier

I can't mount the lower sides until the radiator frame is bolted in, so I'm back to waiting on the rest of my aluminum to show up!
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While I was waiting on more aluminum I decided to redo my workbench top. The old top had gotten wet an swelled up and was coming apart. While I was at it, I figured I'd try a "proof of concept" for the concrete countertop videos I've seen.

My first attempt did not go well, and cracked. So I decided to pour half at a time - made it much easier to move into place as well. I welded in some extra support across the middle, and a couple 45s to keep things square. This Snap-On light my son got me for Christmas is the cat's pajamas!
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Here's a slab in the form
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Getting them into place was interesting, but not terrible.
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Came out pretty good.
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After hearing my aluminum was backordered until late February, I found an alternative source and got back to work.
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Things are starting to come together a bit.
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More of that cutting edge CAD work...
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This piece was about 2-3" too long for my little bender, so had to employ some serious "Southern Engineering", but it came out ok.
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Some more terribly sophisticated CAD...

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Just need to dream up a way to fold & rivet these pieces together in aluminum. Taking a long look at what Andy did for his oil cooler. But don't think I'll be able to fit a toolbox behind mine

This is what my life has come to; "Paper Dolls" for old guys with classic cars!

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I was struggling so with keeping track of which fitting was male vs female, and if any one company had all the fittings I needed in one place...nope! Still need to confirm a couple of bends/angles are going to be workable. I was able to confirm with Mishimoto the Celica radiator can flow either direction, so no need to cross my coolant lines at the front/rear to make sure it flows driver to passenger side...

OMG... hose end fitting planning is
Your radiator shrouding looks great!

Thanks Chris!

Just trying to balance my OCD against limited skillset/tools...I can picture how I want it in my head, but making come out that way is

Look Ma, I made SOMETHING!
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I put the hoses in the headlight buckets and then started chuckling because it reminded me of flux capacitor plumbing in Doc's DeLorean!
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Got my "creation" to mostly fit, and clamped into place.
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Used rivnuts to mount it up for easy removal.
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I measured 6-8 times, and still needed a stiff drink before I drilled those holes! Started with a 1/8" bit just in case I needed to fill it.
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Got it in the correct spot, and it came out ok!
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Looks like I'll need to revisit it in the future to extend the overall height for aesthetics, but looks like it will get the hot air out well enough for now!
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AND I learned the Boys Ranch right across the road has a plasma cutter nobody ever uses. Barn connections...you just never know what you'll learn/find!

Beautiful Mike..... It's really taking shape very nicely.. As I've said before, your detail work is great and will certainly pay off in a high-quality end product.

Thanks Kevin! Feeling my way like a blind guy in a room full of rakes with their tines up!

Fingers crossed that the passenger side outlet on the radiator has enough clearance for the AN adapter and fitting That one's gonna be snug. If it won't clear, I'll be reworking the radiator fit/placement for a third time. Seems like every step takes 4x as long as expected, and costs 2x as much as expected. Quite the journey...I keep joking that our son may have to finish the car after I'm dead and gone!

Built, not bought.

...for the win, everytime!

Thanks Chris! I keep reminding myself I want to do as much of this build myself as I can manage. May not look as perfect, or might take multiple iterations, but I figured it out, and I did it!

Every time someone with a new 911 GT3 makes disparaging comments about my Six conversion, I just look at him and say "Anyone can write a check and buy a car. But not everyone can engineer and build one."

And then I blow his doors off..........

Use this to seal your baffle to the hood. All non-radial piston powered planes use it to seal the baffles to the cowling. Question: is the concrete slab reinforced or plasticized? You're making good progress. Stay after it.

Coming along real well Mike!

[/quote]
Use this to seal your baffle to the hood. All non-radial piston powered planes use it to seal the baffles to the cowling. Question: is the concrete slab reinforced or plasticized? You're making good progress. Stay after it.
[/quote]

Did I miss your link? Maybe it didn't paste...

Assuming your referring to the concrete "countertop/workbench"; It's actually quickset mortar with no rocks in it since I only could do a 1" thickness. I put metal lath in the middle to reinforce it. It's basically a POC to see if I could pull off doing our bathroom counters. I did add flow control to make it flow a bit better, and tried to use the least amount of water I could get away with (meets DOT requirements, whatever that means!). I cast the bolt holes for the vise in it using dowels. So far so good. I've hammered out some aluminum on the vise, and I've been clamping and bending the aluminum duct on it too. I kind of expected some cracks by now...

Here's where I got the idea:
https://youtu.be/T7mYB6x68DY

Thanks Rich! I need to pick your brain on how you calculated the capacity of your overflow/expansion tank. And, your fuel pump choice...what I've read so far says to size the pump based on HP. Not sure if that's how you went about it, or if you found Subaru specific requirements

Crap! I did forget to post the link. I was doing this on my phone while sitting in the ER. Here you go. https://www.aircraftspruce.com/search/searc...s=baffle%20seal

I chose a basic high pressure Walbro fuel pump. Covers my less than 200 hp needs just fine.
As for coolant expansion, there is a formula for calculating total expansion based upon total volume of coolant and temp. Add in the engine, radiator and hoses into the volume avail. Final size of expansion tank required was minimal so I ran a 1.25 quart Moroso aluminum one. It does overflow into a catch tank at temp which works as it should. No issues yet even on 100 degree days. Good fans and duct work helps a lot. I rarely get above 200 degrees on my temps. I think all systems react differently though.

Ruh-Roh...I hope all is ok on your end!

And THANKS! Replying to 914World while in the ER is above & beyond

My AN adapters and fittings finally arrived. I installed the adapters on my radiator, and did a quick test fit of the elbow on the passenger side (lower outlet)...
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Then into the car to see if it's all going to clear. At first I had about a finger's width below the elbow, but it turns out the radiator was not seated all the way!
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On to revision #3 I guess

Only three revisions? You're far more effecient than I am!
Seriously though, it sucks when those sorts of surprises happen. Just try and remember, a few weeks from now you'll have it solved and it'll just be another story about your build that you can share at Cars & Coffee when people are drooling over your car!
FAB on!

It happens.I'll bet Phil @Superhawk996 has a few stories of engineering mishaps at one of the Big 3. BTW> VW Golf expansion tanks are dirt cheap and will fit your application.

It happens a lot less than it did when I first started. Digital mock up (CAD) came a long way during my career. It still happens occasionally during pre production prototype builds when parts are being heavily iterated and things are hand assembled. By the time you get to mass production an interference like that would be costing millions per day while the line is shut down. Don’t want to be that guy.

I haven’t looked at this thread in a while - wow! Lots of awesome progress. You’ll come up with a rework like Chris said. The car will be awesome and the story will be memorable!

Thanks guys! Appreciate the encouragement

I figure its another shot at enhancing aesthetic/style points...think I've heard that around here somewhere

I'm always excited to see updates on this thread. Nice work @mgarrison !

I purchased that same radiator for my build and was also planning on using the water-neck adaptor with AN fittings and hose. What size AN hose are you using?

A couple of thoughts on your interference situation... The water-neck adapter sure does look cool, but maybe it adds too much length here. Could you use a short section of rubber hose as the transition between the radiator and your AN hose?

What about finding someone to TIG weld a short section of aluminum elbow to the radiator outlet?