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Posted: Apr 27, 2009 7:42:12 pm
brewnog



Hello all

Having been on the lookout for a project for a few months (something interesting and doable) a friend mentioned that he had an old 911 feeling sorry for itself. Having viewed the car a few times I bought it on Saturday. Since then we've managed to find out that it's a 1977 (not 78 as originally thought) 911. The car was originally LHD but has been converted to quite a high standard. The car was taken off the road around 15 years ago after the original 2.7 engine "blew up". An exchange engine (a 3 litre I think) was fitted but the head studs shortly failed. A huge amount of bodywork was done on the shell by the previous owner and as a result the body is sound (just a few patches of surface rust here and there) except for the front wings which are pretty hopeless. The engine looks to be in good condition (it's completely stripped) and most of the parts are with the car though I haven't identified all of them yet! Apart from new wings the car is missing a front windscreen and fuel pump plus whatever else I discover is missing along the way.

My plan is to strip the car right out and have a nice lightweight tourer / occasional track car. I'll hopefully get the bodywork sorted out before the summer ends and then look at the engine over the winter.

Anyway I've shared some photos and I look forward to sharing some tips along the way. If anyone's passing through Stoke on Trent and fancies a brew then let me know and you can join the hoards who have already wished me luck and told me I'm brave!

Best regards

James








Where there's muck there's brass.

Posted: Apr 27, 2009 9:21:31 pm
Pete



Welcome to the forum.

You've taken on a big one there but its going to be a great project to follow.

So what are your detailed plans for the body?  Keep it original or go with a back date look or maybe an RSR look?

And plans for the engine?  I guess you need to establish what you have before you decide what to do with it....

We need lots of pics so feel free to show us lots of before during and afters  :agree:

Posted: Apr 28, 2009 6:21:36 pm
brewnog



Well I must admit I don't have any detailed plans yet! I'm new to 911s (I was looking for a project and it just happened to turn out to be a 911!) so am getting to grips with all my options but currently my vague plan is to strip the interior out and get rid of most of the 'luxuries'. I love the look of some of the 'hot rods' people have done but I'm not looking to create a concours car or polisher's dream. I guess I'll just keep working on the body try and keep it light see what wings I can get (anyone got any knocking around?!) and see how things fall into place. One thing I'm (almost) decided on is the colour; anybody know what the name/code of this blue is? Mine is currently silver it doesn't do anything for me.



The engine is definitely the 3 litre. I am going for a reasonably straight rebuild any upgrades will be at a later date on exhaust/injection system but I need to do my homework first.

I'll start a new thread devoted to the car and keep updating pictures as I go.
Where there's muck there's brass.

Posted: Apr 28, 2009 8:44:31 pm
Pete



I think that colour is Mexico Blue.  Not sure though.  Does look great.  There is also another blue used on the early 911's called Arrow Blue.


How about a 1973 RSR Look:



or a 1974 3.0 RSR Look:



or a 1974 RS look:



Lots to choose from and all look awesome.

Have a look in the for sale area of the forumk for body panels and other things you might need.

Posted: May 04, 2009 7:47:20 pm
brewnog



Thanks Pete. I think Mexico blue is indeed the look I'm after. I've managed to find a replacement near side wing so have butchered the existing one to patch up the off side wing for the time being. The 1974 RS look picture you posted looks more like the kind of thing I would like to do but being on a strict budget at the moment I'm going to stick with the wings spoiler and wheels I've got for now so that I might be able to afford to do the engine a bit sooner. Might be tempted by fibreglass bumpers though! Are these a direct replacement for the standard IB parts or would the wings need modifying around them?
Where there's muck there's brass.

Posted: May 04, 2009 8:03:47 pm
Pete



Mexico is a great colour.

Don't forget to post some pics of the car in its current condition so we can see progress.

Fibreglass panels are a direct bolt on replacement for front wings doors bonnet engine lid spoiler front and rear bumpers.  Like most fibreglass panels they will require a little fettling but should be all straightforward.

Looking forward to seeing this one develop  :agree:

Posted: May 04, 2009 8:48:10 pm
brewnog



Here's a few more pictures including this weekend's work. The bodywork is my first real attempt nothing a bit more weld grind and filler won't sort out! I'm quite chuffed considering there was a big rusty hole there beforehand. The wheels are going to clean up nicely too; the corrosion looked pretty bad but it's only surface deep. A bit of fine sanding and some paint and I'll be proud of those too!







You might already get the impression this car isn't going to be exactly cosmetically perfect but I'll be happy to get it on the road and to have some "character" showing a lot of hard work; rather than a lot of cash put into the car.

Edit: Why can't I put commas into my posts? I want the full host of punctuation to be available to me!
Where there's muck there's brass.

Posted: May 08, 2009 5:14:33 pm
Pete



Awesome work James.  You really are getting your teeth into it.  This is proper hardcore and im loving everybit of it.

I'm really looking forward to it developing more.

Here's another idea for how it might look (C)



PS - I have just implemented an uprade to the forum software and so punctuation bugs, and others, have all been fixed!

Posted: Aug 05, 2009 4:31:16 pm
brewnog



Okay, so due to some stuff going on at work at the moment (global economic meltdown, I think they call it), my 911 piggy bank is going to be suffering for a couple of years.

Accordingly,  I'd like your thoughts on how I should continue the rebuild. The car is currently a rolling shell, and needs a bit of light bodywork, a full respray, an engine build, and a few bits and bobs, but ultimately I'd like to put a fibreglass RSR-esque kit on it, and then splash out on some wheels, seats, dampers, and other luxuries. My options, as I see it, are:

1. Do minor bodywork to a fair standard, and patch the paint up. Build the engine over the winter (funds are ring-fenced for that!), re-assemble the car in spring, get it on the road and use it. Depending on how well it drives, and how much I end up liking it, I could then run it for a year or so until I'm in a position to splash out on the fibreglass and a full respray.

2. Build the engine, and scrimp/scrounge/save until I can afford the fibreglass and professional respray, and then rebuild the car, bearing in mind this could be an additional delay of 2 years or so.

Thanks!
Where there's muck there's brass.

Posted: Aug 06, 2009 9:24:19 pm
Davy-D



HI Brewnog
I don't envy you the task of reconstructing that without a lot of expensive out work , I am just reaching the closing stages of phase one on my project and it is plain to see that an engine rebuild is VERY expensive on top of everthing  else, one option you might have is to cut your losses as I did and sell the 3.0 engine and find a good running 3.2 this will give you an extra 40-50 hp and great potential as they can be found for about 2.5K( even a cheap re-build could  cost more than that) and  not a lot more for what should be a really good one ,you could  find a set of Bilsteins, for about £400 or possibly less at a good breakers.
the bodywork is the next killer and  it looks like you have the narrow arch car 2.7L which is restricted on wheel size . The RS/SC style bumper kit  would not fit easily at the back so retro might not be as dramatic as it seems  a non original car(it looks like you are already working on the front wings). you can find a good set of 7 & 8 x15 BBS for a couple of hundred which although not pretty they work well and free up funds for other mechanics the biggest cost saver is getting your hands dirty and I found that stripping and cleaning the suspension , brakes ,  steering and prepping as much as possible  means that the specialist can do his work quicker and at 60-90 £hr  that's worth having. Finally after getting estimates and doing sums you can guarantee that the unexpected will boost the cost by 20% as I found when my engine arrived with a G50  flywheel
which meant a whole new assembly and similar other little hiccups else were all costing more time and money

Posted: Aug 06, 2009 10:15:59 pm
brewnog



Thanks Davy, I appreciate the comments. Your thoughts about the engine match those I'm getting on another forum. I'm at least going to look around for a 3.2l engine, the cost of which I could offset with all my engine parts.

Most of the running gear has already been completely overhauled so I don't have to worry about brakes or suspension (except maybe the shocks, and the master cylinder) for a while. The front wings are now done to an acceptable stage; I repaired one, and replaced the other with a fair second-hand wing. They won't be passing any concours events, but a blind man on a galloping horse wouldn't notice, so I'm happy until such a day that I can afford fibreglass bits.
Where there's muck there's brass.

Posted: Aug 06, 2009 10:29:54 pm
Pete



Hey James -

Im with Davy.  A 3.2 transplat or even a 3.6 transplant will be more cost effective.  My engine started life as a 3.2 and I have have used it as a basis for creating my race engine.

The 3.2 is pretty bullet proof.  You should be able to pick up a 3,2 with engine management and loom for c. £2,500.  It will deliver far more power than the 3.0l and it will give you better fuel economy and will lay down the power more smoothly and evenly over the rev range.

Like you say, you can offload your current engine and get some money to pump into your project.  :agree:

Posted: Aug 11, 2009 8:06:50 pm
brewnog



Decided to go ahead and patch up the bodywork. I'll try and get the car on the road so that I can see how it drives, and whether it suits me or not, before investing heavily in fibreglass bodywork and paint jobs.

Got loads more enthusiasm for the project again now, so carried on with my wheels this week!



Also bought a stack of colour-matched rattle-cans which aren't a million miles away, I can carry on now piece by piece.

Thanks!
Where there's muck there's brass.

Posted: Aug 12, 2009 6:50:11 am
Pete



Hey James -

I think you have made the right choice.  Get he body domn and driver her for a bit to see how she feels and then decide from there.

The wheels look good.  Very nicely done.  Get some tyre wall silk on there an they'll as new.

I did a refurb on my Fuchs.  Here's my guide.  This is for Fuchs but there may be some tips in there that you find useful.

Keep up the good work.

Posted: Aug 12, 2009 5:17:46 pm
brewnog



Thanks for that Pete, looks good.

My tyres are brand new (i.e. never been driven on), but have spent the last 15 years sitting behind someone's shed in the rain, and are so perished they don't even hold air any more. Just keeping them for now so I can move the car if I need to, I'll buy new tyres as I get to the end of the rebuild.
Where there's muck there's brass.

Posted: Aug 14, 2009 12:34:03 pm
brewnog



I'm on a roll this week! Must be the sunshine and cold beer.

Been touching up various bits of paintwork, but I've done the front near-side wing this past few days. Just needs a bit of T-Cut to get the shine on I think.

Where there's muck there's brass.

Posted: Aug 14, 2009 5:14:40 pm
Pete



Nice work James.

I always find cold beer a good incentive to do work, but only if you limit the numbers, or it has the opposite effect  :blush:

How are you doing the painting.  Aerosols or a proper spray gun?

Posted: Aug 16, 2009 5:04:51 pm
brewnog



I've decided on aerosols. I've got a spray gun, but I think my compressor is too small for it, and if I were to use a spray gun I'd want to do take a lot of time, do it indoors, and do a really good job. My garage would be too small to spray it in, so until I have a big house with a big garage I can't see myself doing a proper spray job.  Rattle cans are giving me a pretty good finish (in keeping with the character of the rest of the car!). If the car's any good when it's finished, I'm going to get it resprayed at some point in future anyway.
Where there's muck there's brass.

Posted: Aug 17, 2009 9:35:42 pm
JK



Coming together well mate, keep the updates and pictures rolling

Posted: Sep 06, 2009 12:44:04 pm
Pete



Hows the project comming along James?  Any more photo's?

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