December 7, 2007
has been applied to both doors and the hood. Now, Andy is
making sure that the hardware and doors all work properly
before final paint. Since this photo was taken, the hardware
has already been sent to the plater.
fits perfect, but will stay on while the gas tank is being
installed. The opening for the gas cap is important. So, silver
paint won't be applied until everything is fit perfectly.
That's Monday's project. I have now made the fiberglass sheet
metal for the 6-cylinder engine.
parts are trimmed, I'll fit them to the engine. Here is Tom's
new defroster control.
the headlight backing cover. It goes in the inside of the
fender well and protects the back of the headlight bulb. These
have been replaced or altered because of the size of a different
light bulb. The main cause for destruction is that the wheel
kicks anything it can and damages this part. I had one good
original cover so I finally made a set of molds to re-make
red tooling gel applied to the mold, which was made from the
above cover. The photo on the right shows the negative and
positive mold, which has got black gel coat covering the surfaces.
is made with two layers of 3/4 oz. mat and one layer of the
light ounce German weave cloth. This part was originally plastic,
which is why they've all since disintegrated. With the two
piece mold, the part is smooth on both sides, retaining the
exact shape and surface as the original, but 20 times stronger.
I guess I could have had injection molds made, but then the
part would be plastic again and not as durable. Making the
two piece mold is not a simple project, but after paint, no
expert could tell the difference without a saw!
the layers are laminated to each side...
is squeezed in a vise, which will induce the perfect part.
the last headlight cover for 090 because 068's have already
been made. I only have two more to make for 119, but that
could be ...who knows when.
the engine for 090. We used fiberglass sheet metal to keep
it light and to give it a semi-official look. Of course, this
car has its original engine (4-cam / 4-cylinder) sitting on
a shelf. The 6-cylinder engine is a better power plant for
any 904. In fact, the 904 was designed for the 901 type 6-cylinder
engine. Porsche had an abundance of 4-cylinder power plants,
so they were the chosen engine for the 904. Of course, some
of the later 904's had 6-cylinders installed and a few of
the earlier 904's actually had the 753, 8-cylinder Grand Prix
engine installed. This made the 904 pretty versatile to drive
and to race.
an oil filter instead of the factory grenade filter. This
way you can just change the filter and disassembly and clean
the micron filters. Remember, this engine didn't come with
the car, so changing a few items to more modern parts is a
necessity to keep the car more serviceable.
The engine is a
twin plug with more compression and more camshaft, but simple
enough to be a 50,000 mile engine. Dependability is important
because this car will be driven in rallies and track events.
I'm sure it might even make a few trips to the super market.
Note the small fan. We like these engines to have some coolness
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