Project 911

Convert 2.7L Narrow Body 911s to 965 Wide Body
 

Arrival In CAIRNS - September 2007
Narrow Body Porsche 911s
Fitting Wide Body Rear Guards - September 2007
The rear guards were steel items imported from Denmark. The guards were trial fitted with the standard body marked in preperation to cut. The new wide body guards were removed and the standard body was cut with angle grinder and cut-off disc. Paint was removed from edge of both standard body and new guards to bare metal. New guards were fitted once again and MIG welded into place with stitch welds. These welds were then grinded to be flush with the panel of the new guard and then painted with etch primer to assist in preventing rust. Paint was removed from the area around the join of these two panels and the pre-paint preperation of body-filler and primer application commenced after rubbing down the area with thinners to remove any contaminants. The new guards were given a final coat of primer-filler and then sanded with 240 and then 600 grit sandpaper to ensure a smooth surface.
Roll Cage Preperation - October 2007
The 4 point half cage was purchased from an imported cup car and was modified by welding in a 2inch/3.6mm wall thickness galvanizede section of pipe as a cross brace to aid in rigidity. The cage was test fitted in the car and mounting holes were drilled into the chassis. The cage was removed from the car and prepped with etch primer and primer filler ready for the paint shop.
Fitting Wide Body Front Flares - October 2007
Once again, these flares were imported from Denmark and were a weld in steel item. Guards were trial fitted, marked and then removed. Standard front guards were cut from the car and the wide body flares were welded in place. The panels were prepped in the same way as the rear wide body process.
Trial Fit Wide Body C2 Bodykit Front/Rear Bumpers - October 2007
C2 Fibreglass replica bodykit consists of front and rear bumper as well as side skirts and rear pods. The front and rear bumper were taped in place to show the fit quality prior to being primed and properly installed for the final paint work.
Fitting Rear Bumper - October 2007
Fibreglass rear bumper sanded to remove gel coat then primed in surface primer. After 2 days it was sanded with 320grit snadpaper to smooth the surface and re-primed with surface primer. Left for another 2 days for the primer to penetrate the fibreglass, the bar was primed again with filler primer to fill in any scratches and registration marks. The bumper is secured in 2 main areas;

1) across the centre section at the rear of the car (Where the reflector goes between the tail lights) the top section of the bumper is secured with 10 x 20mm long self tapping screws with oversized washers on the fibreglass side. A 700x200mm 2.5mm thick aluminium plate is then fabricated and secured over the top of these 10 self tapped screws with an overhang of 170mm protruding inside the rear bumper lip and fastened in place with hex nut self tapping 30mm broad head screws. All of these screws are fastened through the bumper and the aluminium plate into the body of the car above.

2) At the lip of the rear flares the new rear bumper is secured in place with 4 (2 on each side) 50mm long / 6mm wide stainless steel bolts fed through a pre-drilled hole and tightened onto a oversized washer on the fibreglass side. These bolts are spaced 8 inches on each side.

2.5mm aluminium strapping is fabricated and bolted to the base wheel arch end of the rear bumper and then self tapped into the body of the car in the wheel arch to add extra rigidity to the sides of the flares.
Fitting Side Skirts - October 2007
Fibreglass side skirts are stripped of gel coat and primed. Left for 2 days and then primed again with a final priming with primer filler being performed 24 hours after the 2nd prime coat was applied.

Skirts are trial fitted to car with tape and marked. With the skirts aremoved the area which will be underneath is sanded, masked and then painted with acrylic white to seal the panels. Skirts are refitted and the guide holes are marked and drilled. These holes are then sprayed with etch primer to ensure no bare metal is left exposed. Side skirt rear quarter pods are cleaned with wax and grease remover and the under side is coated with sikaflex in areas which will contact with the panel of the car. The rear pod is affixed to the car and the bolts behind the guard are tightened which holds the pod tight for the sikaflex to cure properly.

The main side skirt piece is thickly coated with sikaflex and then pressed onto the sil of the car. There is only one guide screw for this part which is fastened inside the front guard. To ensure the skirt sits flush with the sil it is weighted with lengths of timber weighted with bricks to hold the skirt hard up against the panel.
Prepping Doors - October 2007
Both doors were dented and scratched from general wear and tear. Using an electric sander, paint was removed and any uneven areas were filled and sanded back flush with the bodywork contour. The panels were primed once and sanded back with 320g sand paper to ensure a smooth surface for painting.
Removing Glass - October 2007
All of the glass is removed from the car. Due to the perished nature of the existing window seals they are discarded and new items are ordered.

The black aluminium trim pieces which frame the windows and sils are removed and sent to the powder coaters for repainting.
Finishing Rear Guards / Prepping Engine Lid & Roof - November 2007
With the glass removed the window sills are cleaned up and smoothed. 2 signs of rust were visible at the base of the rear window mount under the window seal. These were grinded back and treated with rust converter. The whale tail is removed and sent off to be bead blasted. Rear guards ans engine lid are smoothed back and primed. This is followed by a rub back with 320g sand paper to ensure a smooth surface.

The rear section of the car is now ready for the final painting.
Trial Fitting Front Bumper With Rubber Seal. Priming Front Guards, Doors & Front Bumper - November 2007
Front Bumper is sanded and reprimed with its final prime coat. Front guards are resanded and filled where necessary. Both doors and front guards are primed with a final coat.

Front bumper is test fitted with the Porsche OEM 964 turbo rubber bumper seal. The seal is designed to fill any gaps and is a true test of whether the weld on flares and the fit and finish of the fibreglass front bumper is suitable. The seal fits near perfectly and the bumper is fastened in the centre with bolts and the predrilled holes to fasten bolts on the sides are simply zip tied so the bumper can be dropped for the final paint process.

 

 

 

 

 

 




Refitting And Priming Bonnet And Finishing Roof Prep - November 2007
Bonnet is refitted, alligned, sanded and primed along with front sil and front section of roof. All painted areas are rubbed back with 320g sandpaper once the paint had dried.

 

 

 

Paint Shop - Final Guide Coat And Prime - November 2007
Car is sent to the paint shop for the final stage of the paint work. A guide coat is applied and then the process of removing low spots commences. The drivers side door sits a fraction below the sil line of the rear window. This is rectified by repositioning the guard and twisting it up into alignment which in turn raises the door line slightly. Because this model was not fitted with a passenger side mirror a template is drawn off the drivers side mirror fixing points and a mirror image of these holes is marked and drilled on the passenger side.
Paint Shop - Final Prime in spray booth - November 2007
A final prime is applied in the spray booth. All low & high spots on the panels are now fixed and the bodywork is level. This prime coat will be given a final rub back in the morning.
Paint Shop - Painting inside door jams, bonnet & engine lid - December 2007
The car is masked up and the internal areas which require paint are painted and left to bake overnight. This is done so that the external colour can be applied in a continuous motion across all seams.
Paint Shop - First External Paint - December 2007
The first external paint application in spray booth at paint shop. The mirrors, bonnet, engine lid, roll cage and sunroof panel are the next to be painted.
Refitting Whale Tail, Mirrors, Headlights, Door Handles & Fitting New Headlining - December 2007
With the car now back from the paint shop in the safe confines of my backyard it is time to refit the ancillaries before the auto electrical work is carried out. The rubber edge of the whale tail is thoroughly cleaned and re attached to the fibreglass framework. This is then rebolted to the car. Door handles are reattached as is the drivers side mirror and the newly positioned passenger side mirror. Headlights are fitted and at first are fitted to the wrong sides making the car look like an inbred retard with crossed eyes. This is quickly rectified.

My new vinyl perforated headlining arrived from Germany some time ago and is now being fitted to the roof lining with the use of upholstery adhesive and many dog clips to tension the lining as the adhesive cures. The headlining has been folded in a bag for some time so I hope the creases will straighten out after some time in fluctuating temperatures.

Something which is apparent is that the colour speed yellow (or speed glebe if you want to be exact) is a colour which dramatically changes hue in different lighting conditions. The images in the last entry in the paint booth were under fluorescent lights, these new shots were in natural light at dusk.
Sunroof Seals - December 2007
Sunroof seals (oem) arrived and are glued with adhesive to the body and the sunroof itself. Sunroof vinyl cover is prepared for internal of the car.
Installing RS Carpet Kit & Roll Cage - December 2007
Carpet kit arrives and contains 16 carpet panels with no instructions. The carpet panels must be installed in a certain order so that some pieces overlap others. A few trial and error attempts are made before the rear section of the carpet kit is glued in place.

The roll cage is fitted and matches up to the existing mounting holes from the initial trial fit. It is bolted through the carpet with new stainless steel nuts and bolts through a 2mm thick metal plate under the car.
Refitting Glass - December 2007
The business that has been storing the glass since they removed it is called back to reinstall. New front, rear and side window seals are purchased and installed along with new bailey channels and guide felts.

All window frame work has been stripped and powder coated black.
Fitting 964 Taillights - December 2007
Being a G Series 911 to 964 turbo body update novice it was overlooked that the rear beaver panel between the taillights needed removal to properly fit the update reflector. Normally this would have been done prior to painting so it was a bit of a pain to have to remove it now knowing that paint would be damaged.

All in all the panel came out okay with lots of careful cutting and twisting. There were a few mishaps but they should heal with touch up paint.

The taillights are positioned in place to make sure they fit.
Instrument Cluster Update - December 2007
The standard VDO instrument cluster was considered a bit too dark for the rest of the interior and therefore a white face update kit was ordered purely for aesthetic reasons. The bevel edges of the instruments needed to be pried open carefully, the needles removed and the new faces simply replaced and/or fitted over the existing faces. The speedometer has been sent away to be recalibrated to suit the new 270kmh readout.
Ancillary Rewiring - December 2007 - January 2008
Local Cairns genius Ian Swinkles was called upon again to use his talents on replacing the ancillary (Lights, switches etc.) wiring. This process included a complete update to more modern design fuses and relays as well as a replacement of much of the old wiring loom where necessary.
HID Headlight Upgrade - January 2008
Considering the advances in light technology since my 1977 car was assembled it was a no-brainer that the headlights needed to be upgraded to more modern devices. Using Bosch Hi/Lo 6000k HID's the lights now turn night into day.
Trial Fitting Front Wheels - January 2008
Obviously this car was not going to settle for 15x6 cookie cutter wheels. These new wheels are Italian Techart 3 piece alloy wheels. (18x8 front and 18x11 rear). In order to fit these modern offset designed wheels to an early car wheel spacers were required. Wheel spacers are legal in Queensland as long as the vehicle manufacturer that make the vehicle offer wheel spacers as OEM parts. Porsche is one of the only companies that supply wheel spacer plates as OEM parts so using them is legal. The wheel spacers on the front are billet aluminium 1 inch thick single piece items and with the use of 72mm Porsche wheel studs they are a flush fit with the guards and encounter no rubbing in the arches or against the suspension.
Cleaning & Painting Suspension & Brake Parts - January 2008
Front monobloc Porsche Brembo brakes from a 1998 911 Carrera (996 - watercooled rubbish) were purchased second hand and cleaned, degreased and then painted yellow with high temperature resistant paint. Once the paint had dried the calipers were lightly sanded with 600g sandpaper. Porsche logo alloy decals were ordered from the US and secured to the caliper face.

Brand new cross drilled rotors are oiled to keep free of surface rust until installation.

New koni shocks are installed in the standard strut assemblies which are thoroughly cleaned, degreased and painted with the same yellow as the calipers.
Refitting Front Suspension & Brakes - February 2008
The A-Arms cleaned and painted and have new ball joints pressed in. Original and old rubber bushings are replaced with solid poly-graphite replacements that require a lot of coaxing to fit. The bushing on the fromt crossmember side was especially difficult to press in and after trying "friendly" taps with a hammer and heating the aluminium crossmember with a blow torch to expand the hole it still wouldn't press in. Eventually placing a threaded steel rod through the A-Arm where the torsion bar would normally go and, with the aid of a nut and washer at each end, torquing the bushing in place by tightening the nuts at each end.

A new 23mm torsion bar was purchased to replace the standard 18mm item and it is greased and tapped into place. The height adjustment is an unknown entity until full weight can be exerted on the front of the car (fuel tank etc.) so the ride height is left unchecked at this stage.

Front strut is secured in place and locked onto the ball joint. The rotor, hub and caliper are assembled onto the installed strut. New Lemforder tie rod ends replace the worn out old ones and a solid whiteline sway bar is fitted into new polyurethane bushes.
Refitting Front Wheels & Guesstimating Front Ride Height - February 2008
The front wheels are fitted and the car is lowered. It took 5 goes of torsion bar adjusting to get the left and right 'centre of wheel to guard' height even. There is only a 4mm difference in ride height from left to right. (This will be rectified once the suspension has its final tune when the car is engineered and inspected.
Finishing Carpet, Installing New Seats And Steering Wheel - February 2008
RS America door trim panels are fitted over plastic membrane. Interior carpet trim pieces for the front of the car are glued in. New retrimmed leather seats are bolted in place. Momo steering wheel is fitted to column with Momo boss kit.
Fitting New Rear Shocks, Fitting Rear Brakes, Painting Engine Bay & Rear Wheel Arches - March 2008
Because of the size of the hat on the rear rotors and the thickness of the wheel spacer the surfaces that would be visible through the wheel were primed and then painted black. This was to stop the brake hat from rusting and make the whole rear hub assembly look presentable. The engine bay, spring plates, wheel arches, banana arms, torque tube and rotor dust covers were thoroughly cleaned with a wire brush and degreaser before being painted with high temperature resistant black paint.

The new rear Koni Sport shock absorbers are fitted with the use of a jack underneath the spring plate to raise the rear hub assembly to the lower connecting point of the shocks.

The new drilled rear rotors are fitted and the spacers bolted in place. With both visible surfaces of these two items being painted it makes them appear to be just one piece. The 996 rear Brembo calipers are fitted with the pre-purchased brake caliper adapters which convert the hub assembly to a radial mounted brake caliper type.
Fitting Front Brake Ducting & Finishing Turn Signal Lights - March 2008
RSR Brake duct bumper inserts are prepped and painted gloss black. 3 inch wire reinforced rubber flex hose is affixed to the back of the ducting panel. The front bumper is trimmed to allow the hose to go through and the the ducting is fed through. The ducting panel is affixed to the bumper. The side reflectors and indicators are attached and secured.
Car Moved To Front Garage For Engine & Gearbox Install - March 2008
The car is towed from the back of the house to the front where the surface is more forgiving to installing a motor and gearbox.

The engine going in is an original 930 Turbo engine which has been professionally rebuilt by K-Tec. The rebuild cost alone was $20,000.00. The engine will be mated to a late model Carrera 5 Speed, oil cooled gearbox with a lightened flywheel and pressure plate as well as a heavy duty clutch.

The car is lifted from the back and rested on 4 tonne car stands which stand atop of timber blocks to get the most height. Believe it or not, this is how Porsche tell you how to install and remove the engine!
Fitting Engine & Gearbox - April 2008
With the car raised and ready the engine and gearbox are installed. First the flywheel, clutch and pressure plate are fitted and then the gearbox is secured to the engine. A pallet jack is used to wheel the engine and gearbox assembly to underneath the car and trolley jacks are used to lift it until the rear engine and mounts follwed by the gearbox mounts are fastened. The new bigger and stronger drive shafts and CV's are fitted and the gearbox linkage is coupled to the gear selector shaft. The Modena gated shifter is fitted to the car.