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Rear Clip Pins
Do not want the rear clip flying up so I made some rear clip brackets. Got to keep practicing tig welding the aluminium so I was happy with the result.
Update : 12th November, 2011
Lights & Wipers
Continuing from the work from Page 1.
Decided to tackle the lights. Made up adjusters etc for the headlights and it has worked very well. get behind the lights and I have 3 knurled adjusters to aim the headlights. Parts with holes shown are glassed into the body.
For the driving lights I used Narva light enclosures to hold the Hella 5.75" lights. They allow full adjustment and come with a chrome bezel that looks great.
After fitment it all looks great. Still need some indicators.
Then I started on the wipers. I really did not like the cable drive wipers. Too much work and too many parts. Used a direct drive geared wiper motor. Has auto park etc, great unit. Made up some brackets and a special adaptor at the end for the wiper arm I'm using and it fitted great.
In the image below you can also see my reversal of the spider fitting system. I did not like the screws all around the front of the spider, so I reversed and reinforced the lip under the spider and fasten under the dash. My dash comes out with minimal fasteners so I preferred this. The seal will be trimmed later.
The wiper arm is a NOS 1985 Mercedes 380SL stainless steel arm mated to a Ford GT wiper blade which closely resembles the originals. I think most arms were black so I will most likely powder coat it later.
Update : 1st November, 2011
More Door Work
I manufactured some door handle assemblies and fitted those to the doors. These handles can be easily removed from the door by undoing the shoulder bolt fitted.
A small interior handle and recess in the top of the door to pull it closed were also added.
This handle is connected by a cable to the Porsche door lock assembly. As pulling this handle operates the mechanism separately to the outside handle, as should be the case.
I then looked at door boxes. I really did not like any of the door boxes available so I made my own moulds.
Fibre glass was applied to each of of the molds and removed leaving a perfectly surfaced thin and light box. So that I could get a perfect match to the doors they were glassed in as shown below.
Then the boxes were then carefully cut out of the door to make a flange that matched the contour of the doors perfectly. The result is shown below. Fasteners are on the inside and the box has a perfectly spaced small gap all around. When they are painted black the gap will not be as visible.
Now onto the dashboard (see interior)!
Update : 31st May, 2010