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Project 387


timbobalobox

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With work/Father's Day etc I didn't get anything done since the last update, but did a bit more tonight;

Offered up the rear clam as I needed to trim a bit more (hence why its not sitting flat as the where the curved part goes flat in the wheel arch needs to sit under the existing sill)

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then stuck the front on too, because well, I got a bit excited :D :D 

 

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You can see how much higher the front sits above the windscreen - I've got someone coming over to remove/refit the new screen as I took one look at all of the trim I could ruin and decided to call in the pros!

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The valance sitting on the top goes on the inside of the screen - I think I'll get this covered in leather to match the dash.  Next up is to cut out the remainder parts from the new body (fuel filler etc), finish the electrics and change the springs over.  

I might be speaking too soon, but fitting the body actually feels quite close :) 

Found this for a colour option - still undecided!  Walter Roehrl's 356 (with a 911 turbo engine in 😎

 

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15 hours ago, timbobalobox said:

Found this for a colour option - still undecided!  Walter Roehrl's 356 (with a 911 turbo engine in 😎

 

IMG_4109

 

 

LOL. Can you imagine bimbling through the Black Forest in your Boxster on your European tour and being overtaken by a creaky old 356 driven by some pensioner in a flat cap, and then deciding to burn him off in order to teach him a lesson.

It could end very badly!

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2 hours ago, Wish said:

100% love this ….  
The worrying thing is your making it look too easy. 

Thank you 👍  I'm only posting the good bits though 🤣🤣  There is many a moment where I'm wasting time, scratching my head, trying to fathom the way to do something.

I have been quite pleased with the progress so far, however I think the hardest is yet to come... :( Apparently getting the body fitting perfectly is a bit of a challenge!  I'm hopefully going over to Iconic tomorrow to see how he is getting on with his customer's as it's fortunately at a similar position to mine.  Moving the clams around the garage is a pain and whilst not heavy, definitely an extra pair of hands makes it muuuuuch easier.

I still need to work out wiring the door solenoids as they go from mechanical where the handle pulls on a lever on the latch, to an actuator pulling a cable, operated by a new door switch (a tailgate release for a mk2 focus nonetheless!)

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Been following this on holiday in Turkey this last week,  great thread and coming along nicely..  At one stage I thought you may have already painted the rear clam clay grey....  Looks awesome as does that 911 turbo 356...!!!?

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15 hours ago, Daboy3000 said:

Liking that green, will work with the black interior too. 

 

14 hours ago, red rocket said:

^^^ love the Green!

 

To be fair this was my wife's idea - can't even take the credit for it!  I think the fibre glass benefits from a bit of metallic fleck in the paint, so it will be a good option 👍

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10 hours ago, iborguk said:

@timbobalobox Just wow, love the way it's coming on, excited for you 😀

Thank you - really enjoying doing it, and trying to find excuses to slope off to the garage whenever I can!

I've got a chunk of free time tomorrow so hoping to get quite a bit more done 👍

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43 minutes ago, skoosh1970 said:

Been following this on holiday in Turkey this last week,  great thread and coming along nicely..  At one stage I thought you may have already painted the rear clam clay grey....  Looks awesome as does that 911 turbo 356...!!!?

It actually looks good in the grey!  The finish on the fibre glass is lovely.  I'm just off the phone with a painter who is local to me and gets great reviews - I'm really keen to get a nice finish on it, as this is what will set it apart and make it look special as opposed to something I put together 😁

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23 hours ago, Wish said:

Will you get a dust coat on the underside in the chosen colour before fitting.

I don't think so to be honest, it's going to be a trial and error method of putting the body on and a while before it can go to paint - once the body is ready for fitting it's bonded to the shell so access could be an issue.  Also all of the interior trim/boot liners/wheel arches are re-used so there should be much to see :)  

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As ever, not quite as much done today as I would have wanted to - the noticeable progress has definitely slowed too!  Lots of little fiddly bits that are time consuming, but don't look like much.

Windscreen was taken out on Friday night - I was impressed it came out in one piece, so I may try and sell this (if there is much of a market with most people going via their insurance when they need a replacement).

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 I also started to mark out/pre cut the screen valance - it's quite tricky to get a decent cut by going slowly as the grinder gets so hot it melts the plastic, which then cools leaving a bad finish.  Ended up cutting shy and using a dremmel to clean up.  The fibre glass valance will be sanded/sprayed black (the finish is really quite good already).  I *might* try and cover with leather to match the dash, but seeing as the original part I've cut is plastic, it might not be necessary.

With the valance in (rough) place) - this will be bonded down once I've applied the finish.  Wiper mechanism out too.  You can just about see the flexible pipe on the top right - this is an extension to the washer fluid reservoir filler as it needs to be further into the frunk. 

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You can also see where I'm reshaping part of the wing for the angled fuel pipe to clear - it needs a bit more doing to get it right.  Also begun to tidy up the wiring going to the new side repeaters having spliced it into the front loom.  Plus the  trusty Dulux tins holding up the brake caliper :D 

Bit more cutting the front out to ensure the new clam sits snugly - you can also see the airbag sensor (blue with a yellow wire) with a self tapper as this used to mounted under the front wing.

 

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Spaghetti junction!  I'm using wagos to test the circuits then will solder/heat shrink once all working.  This covers the front indicators, side repeaters, front dipped/main/side lights and also driving lamps (with the main beam) 😎

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Drilled and tapped door restrictor spacer on

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And more cutting/shaping!  This is roughly the shape and will reach the new wings (you can see it's a wider track than the original), and just needs neatening up 

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That's all for today - might get some time tomorrow evening to mess about a bit more with the electrics as I'd like these done and tested

 

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Another week gone by, and another feeling of not having achieved much!  Managed an hour or so through out the week, then a good chunk today.

The time has mostly been taken up by wiring, changing the springs and getting the body ready to go on.  
 

Striped the old wiper mechanism off - due to the new screen a new one is needed.  I've got this now from Iconic, just need to get a photo!

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Springs finally changed (and now back on the car) - the top plate was seized on, so I had to drop them to a local specialist who managed to get them loose.  

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Managed to snap the head off the bolt that holds the brake line to the hub, so needed to drill/tap a replacement 🤬

An example of the little things that take time to make up - off the shelf light assemblies needing modifying so I can wire them up (this is the reversing light - there is an identical one for the fog)

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Windscreen valance getting filled/sanded/sprayed

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Trimmed the new clam down where it came out of the mould - this is duuuuuuusty work!

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Cut the vents out (I cut rough, then tidied up with the sanding disc)

Took over the drive as it was a nice day!

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The bit just below the front clam is a valance that bolts to the bottom (it's currently upside down and needing the vents cutting out). 

A very naked Boxster!

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Tested the lighting this morning, and most of it works...  Need to go back to fault checking for the side lights and indicators (which I think I need a ballast for the side LEDs).  Looking forward to getting this a bit more organised!

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Sooo close!  Just needs a touch more trimming and it should be a nice fit.

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I still need to wire up the new door solenoids (takes a feed from the window mechanism), but as the door skins need to go on first to line the front and rear clams up, and having them off makes it a lot easier to do, I'll mask the surfaces and use a small amount of adhesive.  I'll be able to peel it off and sort the wiring later.

Also picked up the speedster humps and the last of the brackets - it's slowly coming together now.  As it's fast approaching my busy time of year for work, in a perfect world I'd like the body on and ready to paint in the next couple of weeks so I can leave it with the painters.  Then have it back just in time for the rain in autumn 🤣

Have a good week all! 😎

 

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Managed a couple of hours tonight - the rear clam has had to go on and off a load of times to get the lines right, trimming a bit each time...  Painstaking (and damn awkward) but getting there slowly.

Door skins tacked on with fast drying epoxy and masking tape,  so I can use this as the datum for the clams

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Then as usual got excited so put the boot lid, tonneau, spoiler, speedster humps and tyre on!  Panel gaps line up nicely once pulled straight.  As the wheel has no load on, the gap is way too big for the arch and will sit much more snugly.  A little more tidying up around the arch and should be ready for bonding on soon - the point of no return!  Then onto the front.

Finally sorted out the side repeaters which needed a ballast as mentioned.  Also worked out the problem with the side lights - just the door actuators and front indicators playing on my mind now!

 

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14 hours ago, timbobalobox said:

  A little more tidying up around the arch and should be ready for bonding on soon - the point of no return!   

 

I think you passed that point a while back. LOL.   

 

Looking really good.  This would have been a very successful youtube series.

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A bit more this weekend - the rear clam is now bonded on (just at the door end as the rear needs seating correctly when gapping the boot lid).  It was bloody hot work!

Now onto the front...  I put the bonnet in to check the gaps as I go

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As you can see it's sitting a bit high, so I've marked everywhere to trim and will take it off to do so, mitigating the amount of dust in the garage!  You can just see the trim on top of the door (yellow marking tape around it) which raises the profile inside the car.

 From the other side - this shows that it's not sitting right a bit better.  It's a painstaking job marking up the clams (especially in the heat) as they're on and off so many times.  

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The gap between the door and rear clam doesn't look quite right in this picture either - in reality it's almost there and is made worse by the light.  You can just see the new fuel filler in shot too (also below), it's a clever design that uses the original flap.  I managed to break the old hinge removing it which is quite common apparently - £15 to replace so not the end of the world.

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It looks much nicer with the front valance on, but it needs to be off to remove the clam.  The wiring hanging down are for the driving lights, like this;

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I think this is Slate Grey too, which is the colour I'm going to go with - it's the same as the Walter Röhrl one earlier in the thread 👍

So it's getting there... however I've still got a mammoth to-do list that frustratingly has a load of fiddly time-consuming bits on!  Still, it's great fun and an enjoyable project so far.

Enjoy the sunshine all 😎

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