| [ Total Views: 110967 | Total Replies: 437 | Thread Id: 75812 ] |
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 ricola
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| posted on August 4th, 2011 at 08:30 AM |
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The replacement was another early closed deck block WRX engine with td05 turbo, I just transferred all the bits over to the replacement block...
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ricola
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| posted on August 7th, 2011 at 04:56 AM |
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I really wasn't keen on the Porsche 'nipple' lenses so after carefully picking the surrounds off I was able to remove the lenses and make up some
new flat ones from polycarbonate sheet. While they were apart I sandblasted and repainted the rims and they look brand new now.
All back in the car I'm happy with how it's all looking. I painted the dash binnacle as a temporary measure until it's re-trimmed in leather.
I also re-fitted the running board chrome trim and I think it finishes them off nicely.
I also made up a strut brace. Coming off it are a brake reservoir bracket and also a cover to protect the fuel pump and fuel level sender.
Next big job will be the heater but I have to figure out what matrix to use, I need one that is about 100x200mm, any ideas?
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surfbeetle
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| posted on August 7th, 2011 at 07:07 AM |
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Thanks for the ongoing inspiration. Everything looks great. I know you probably already said it, but what type of steering wheel is that and what
are the buttons in the center connected to?
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ricola
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| posted on August 7th, 2011 at 07:33 PM |
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The steering wheel is a very rare limited edition Momo/Alpine part. The centre has infra-red controls for the stereo, it controls Alpine by default
but can be changed to also control Sony, Kenwood & Pioneer.
My dilemna now to do with this is how to trim the interior. I'd like chocolate brown leather but with just a black steering wheel it wouldn't look
right, I'm thinking if I can add some black to the trimwork it might fit into the theme better. I suppose it might be OK with the black strip across
the dash in contrast? I'm also considering doing that bit in wrinkle paint to give a slightly more classic look..
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Flintstones
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| posted on August 7th, 2011 at 09:17 PM |
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Rich,
please, please, please don't wrinkle paint the dash strip. Trim it in black leather if you can.
I'm sure you will be able to incorporate bit's of black into your door trims and seats for an integrated look.
Cheers
D
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ricola
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| posted on August 7th, 2011 at 10:46 PM |
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Lol, you're not a fan of wrinkle then! I'm sure 911s of this era had some sort of textured finish for the middle strip? Re-thinking, it may be
enough that the central strip being black will be enough to let the steering wheel blend in?
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Flintstones
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| posted on August 8th, 2011 at 09:13 AM |
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Hey Rich,
Definately not a fan
I've just sent you an email also
Cheers
D
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ricola
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| posted on August 18th, 2011 at 06:49 AM |
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I've cut into the wiper box cover to build a housing for the heater matrix. The corner piece had to be clearanced for the wiper mechanism and the
tube connects straight up to the stock air ducting so all the stock dash controls can still be used.
Fiat cinquecento heater matrix in place, note the neat positions of the connections down the side of the car.
I initially planned to fit the stock fresh air blower fan roughly in the position shown but when connecting it up to a spare battery it was more a
breeze than a decent flow.
This is the polo heater blower which gave much better flow and will also be easier to mount up to the matrix.
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Flintstones
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| posted on August 18th, 2011 at 12:48 PM |
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Nice and compact
Cheers
D
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ricola
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| posted on October 9th, 2011 at 04:08 AM |
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I finally had enough of the restricted steering, tyre rubbing and compromised steering geometry so found a set of wider front wings in conjunction
with some concentric wheel spacers. I also plan to rebuild the steering rack with adjustable end stops to maximise the lock available. The wings will
also need modifying to provide a better mounting surface for the air damn. From a quick drive around it is significantly better.. The front bumper
brackets will need to be extended slightly to give a bit more space to the wings too but I think it will end up looking better with more flowing
lines.
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ricola
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| posted on November 28th, 2011 at 03:50 AM |
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Bit overdue an update!
Plenty of stone chip was sprayed on underneath the wings and then high build primer, final colour and clear before letting the paint settle for a week
or so and then refitting them.
I actually got some stonechip overspray on the air damn so ended up giving that a full coat along with satin black paint as it could do with the
protection anyway.
All re-fitted!
I don't think the car looks noticeably different but with the wheel spacers and re-done steering rack with adjustable end stops I now have a lot more
steering lock as well as a much more predictable and nice feeling balance to the car.There was far too much negative scrub radius with everything
forced inboard to fit under stock width wings.
Another mod I've done is switch to smaller 5/8" brake master cylinders along with a calculated balance bar position and this has made the brakes
MUCH more confidence inspiring with less pedal effort and a bit more travel!
I made up this metal cover to cover the shifter base and allow trimming, still not sure how I will do it but it's a start.
I've been putting this off for a while... The old vinyl roof shrunk whilst in storage folded up so when I came to close it on the car the stress
broke the wooden bow over the rear window. This meant a new bow and roof!
Bow from the original tooling was sourced from Germany along with a new roof outer skin, in Sonnenland (similar to mohair) this time around and a
change of colour. A fair amount of repair of sound deadening material as well as repainting sections of the roof frame were done at the same time.
Here's the roof ready for it's new outer skin. The foam strip over the bow is to cover up the staples holding fabric to the bow and stop wear on the
outer hood.
Almost there! I'm letting it all settle for a few days now before I get the knife out and cut the rear window aperture out. All seals and wires are
refitted in this picture, just a couple of screws to fit at the base of the C pillars to take up any final slack in the material.
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vlad01
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| posted on November 28th, 2011 at 09:39 AM |
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Sweeeet! 
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE |
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TCR7
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| posted on December 8th, 2011 at 09:29 AM |
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Car looks great, love the new soft top.
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ricola
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| posted on December 15th, 2011 at 03:04 AM |
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Roof just about done now...
I'm going for the light tan colour leather on the right for the interior, I was originally going to go for a cocoa colour but having thought about it
I think it would be too much of the same and some contrast is called for.
Seat backs are a bit marked and as the seats will soon be dismantled for trim now is the perfect time to colour-code the backs to body colour.
The old trim panels were moisture damaged so I've made up some new ones. I will also be making some new moisture barriers to keep these ones dry!!
You can also see in the background I've put sound deadening in the door panels
These are the cut-down aluminium Porsche 944 spring plate covers with much wider aftermarket urethane bushes to better locate the spring plates.
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ricola
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| posted on December 23rd, 2011 at 04:32 AM |
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Seat backs after a lot of work with paint stripper, etch and high-build primer
before finally getting the body colour top coats..
More sound deadening pads fitted to the floor panels and new MDF trim panels made up to fit speakers under the back seat
Door membranes to stop the new door panels suffering from water damage (I've also painted them in yacht varnish before I give them to the trimmer)
Automotive underlay cut to shape for the floor, only lightly glued in case they need to be removed to dry out if I ever get caught out by rain!
The first piece of carpet going in. I've spent far too much time planning the layout in my head to minimise joins and exposed edges to give it a more
OEM look.
First panel finished...
Then on to the tunnel section. I bonded on a metal reinforcement to the handbrake hole, this means I can fit the standard type rubber which will hide
the cut edge nicely and the hole won't get opened up. A bit of foam also stops any potential rattles.
Passenger bit now done, just behind the back seat to sort out. Still undecided what to do about under the bonnet
Front end done. The floor and bulkhead panels will go to the trimmer to have the edges bound.
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Flintstones
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| posted on December 23rd, 2011 at 09:06 PM |
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Colour combo looks good Rich.
cheers
D
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ElusiveStranger
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| posted on December 24th, 2011 at 04:10 AM |
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Looking stunning, Rich!
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ricola
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| posted on March 5th, 2012 at 12:07 AM |
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LSD as received with the gearbox when I bought it, bit of an unknown quantity!
The ramps show it is out of a 964 RS/turbo which means 20% lock on acceleration and 100% lock on overun. This has really helped the car feel much more
predictable and also stable, especially after the suspension unloads after hard acceleration. I was going to have a go at fitting it myself but was
unable to measure everything accurately enough. The trans had different brands of bearing either side of the differential so during the swap I had to
replace: bearings, ring gear bolts (longer on LSDs), seals, oil, shims. With labour that lot added up to £580!!!
The main reason for taking the engine out (other than boredom waiting for the trimmer), was to sort out a minor oil leak coming from behind the
engine, a very common fault with subarus.
Here's the updated subaru part, steel plate and new screws fitted with a sealant. The black screw is supplied with dry loctite on it, forgot to look
why, probably as it was a through hole so needed sealing?
After being messed about by 'Car Audio Centre' for the best part of two months (avoid them at all costs!!) I bought a secondhand head unit from a
friend. I wanted Alpine to go with my steering wheel controls. I ended up with an IDA-X001 which is a media head unit with graphic display and
ipod/iphone controls. Rather than use a wire and screen mount I have hacked up a dock which fits snuggly into the ashtray with minimal mods.
Happy with how it looks! Lucky this head unit has the main control centrally so out of the way of the phone. I'll use it for satnav and music as well
as keeping my phone charged.
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iwantbus
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| posted on March 11th, 2012 at 12:46 PM |
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Wow just went through the whole build and that is very impressive. |
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ricola
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| posted on May 8th, 2012 at 04:29 AM |
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The old 944 CVs were clicking a bit and my plan was to upgrade to 930 CVs anyway. Here are the bits needed for conversion; new stub axles, I already
had G50 trans drive-flanges, custom length axles (16 1/4") in 28 spline to match the CVs.
Here are the GKN CVs, I cleaned up the flanges that came with my gearbox but needed an extra pair. After getting up off the floor after being quoted
£120 each from Porsche I found some cheaper options from prolinx.
CVs are being 'clocked' as this gives them the best alignment relative to each other, just like you do with a UJ.
All ready to go on the car
And fitted!
Clearance is very tight to the coil-over but is pass-able (this is worst case compression clearance). I spent ages trying to get some smaller
motorsport CV boots from GKN only to find that they had stopped making the size I needed!
I've been asked so many times about my cooling system I've finally modified a schematic to show how it is all plumbed up. This system works
perfectly, gets up to temperature fast and stays at a constant temperature. The other bonus is that I don't even have to bleed the system from an
empty fill as it is completely self bleeding!
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Ollie
A.k.a.: Ollie Clarke
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| posted on May 12th, 2012 at 12:01 PM |
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Just found this tread...
Homigod this is amazing
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SebastienPeek
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| posted on May 12th, 2012 at 12:14 PM |
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I agree Ollie, just read the whole thing, absolutely awesome.
Those seats,I think they could find there way into Zelda.
What did you have to do to the rails to get them in?
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Ollie
A.k.a.: Ollie Clarke
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| posted on May 12th, 2012 at 12:21 PM |
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I've been keen to see those wheels on a bug for a while and they look sooooo good!!
(not as badass as yours'll look Seb  )
Kabs rock
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SebastienPeek
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| posted on May 12th, 2012 at 12:25 PM |
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Ahaha yeah, this bug is epic, only bug that I actually like that is a Cabriolet...
Soon Ollie, soon
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ricola
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| posted on May 12th, 2012 at 05:53 PM |
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| Quote: | Originally
posted by SebastienPeekThose seats,I think they could find there way into Zelda.
What did you have to do to the rails to get them in?
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Didn't you notice that I don't have any of the original floors left?! 
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SebastienPeek
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| posted on May 12th, 2012 at 05:57 PM |
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I did notice, was just wondering if you used the same rails or not?
But obviously not
I'll see what I can do to get the seats into mine, will see if I can find anything on them
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ricola
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| posted on May 12th, 2012 at 06:11 PM |
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Send me your email, I have an article on fitting them onto existing 3 point VW mounting if you like...
Rich
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SebastienPeek
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| posted on May 12th, 2012 at 06:38 PM |
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Thanks Rich,
Sent you a PM
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flat_iv
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| posted on May 18th, 2012 at 03:47 AM |
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What year BMW E30 thermostat housing/thermostate did you use? I did a google search and it seems there were different styles used thru the years. I
am all for not having to burp the cooling systems for hours to get the air out. Are you using the ECU to turn on your cooling fan?
Thanks...
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ricola
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| posted on May 18th, 2012 at 04:39 AM |
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I think there was only one choice for the four cylinder engines, that's the one I'm using.. Yes, using the ECU to switch the fan, I was previously
one for using the adjustable thermostat switches but they seem to end up failing and aren't particularly neat.
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