Saturday, October 14, 2006

Project 18 - Fitting the rear and obsessing over the rear bumper

Lots of stuff got done Friday Evening and Saturday Morning. First, the GT-Racing Flares have a wierd cut-out for the torsion bars. This didn't look right to me so I cut them out.

Then I glassed it over.
Then cut the new hole. It still needs to be dressed but it isn't bad.



Next, Chris got his flares from Better-Bodies.com. It's pretty good stuff. The t-bar holes are right but it isn't in gel coat. That's actually a good thing because you don't have to DA off the gel coat before you paint it. He also got spacers since he has turbo wheels. So... we put his wheels and spacers on my car to get an idea of how it would look.





That certainly gives you a good idea of how it will look.

After that we shifted our attention to the rear bumper. As you can see in the picture below, it's too long. Hank should fix this. It's ridiculous. My car may be a hand-built 911 with difference, so they say, but it isn't 2 inches shorter than other 911's. What are you kidding me?

We decided where we were going to cut it and taped it off. Then,

took the air-body saw to it.


and cut the whole taped piece out on both sides.

Now that fits better. We'll have to glass up the gap tomorrow.


Tomorrow, we'll try and finish the front.

Sunday, October 08, 2006

Project 17 - Finishing the Body Kit

The goal for today was to get the body kit mounted. This is a really complicated thing. First, as you will recall from previous blogs we built up the lips so that we could get the bumper and the flares clamped together. Today, we sanded the mating surfaces down so that they were flat and thin enough to mount up without funny gaps.

Next, I drilled some holes in the upper and lower lips. You can see in the picture that there is a pivot point and a slot so that there is some adjustment.

Next, we clamped the flare to the bumper while the kit is off the car. We had previously clecoed this to the car and marked it all out so we knew more or less where to put it. We then drilled the holes in the bumper.

In this shot you can see the upper and lower shop-made brackets. These will be permanently mounted to the car so that the surfaces are flush with each other and strong. This plate will spread the load quite a bit.

The picture below shows the kit all together on the floor. This is then moved as a piece to the car where it is clecoed on.
The exact same thing was done on the rear.

We also moved the rear wheels off of Chris' car onto the front of mine. These are 8's and I'll be using 9's but it gives us a better idea of how everything fits. We also lowered the car a little over an inch. We're pretty happy with the look at this point but the right side is off about 1/4" or so on the passenger side.


As you can see from the picture below, I'm getting pretty close to finishing. Yes, that's a dog bowl. Got a better place to keep the receipts?


I don't have a picture that shows it because we were looking at it after we had blown out and mopped the shop, but the rear bumper is a disaster. It looks great from a distance but when you fit it up and start looking it really is a mess. We're going to have to section it and shorten the whole thing by over 2 inches. And, as if that wasn't enough, the rear wheel arches on either side don't match. One looks good, the other looks like crap.