The project I'm currently working on, 71 911

[Carmagic]

I decided to cut out the old rear shelf on the 71 911, and fit in the new piece.





On the left side there was some rust and I had to cut out some old metal and made some new pieces to weld in.











I also needed a new section for the fire wall.





At the right side, I removed the reinforcement piece for the roll bar mounting plate. This is what happen after 10 + years in between the 2 sheet metal pieces.



It was only surface rust, and I was able to clean it up.



I opted for the later model shelf since it's a bit higher and will give some extra space in the engine bay.



Cleaning up the original hinge mounts for the deck lid.



When I had the rough position, I drilled some larger holes in the self, so I could move them a bit to make sure they were in the right position for the deck lid hinges.



A few adjustments and the lid did actually fit nice. I had also to make small piece for the section at the left between the self and the window frame.





Here it is all finish welded in.



Here is my collection so far what I have removed. It should not much be added at this point.



Cheers
Engelbert

[W5Hans]

Hi,
I find this so much fun to follow super nice that you let us watch along and good luck.

[Ix_]

Thank you for sharing this with us. I hope you keep the car the same color (Conda/Signal?).

Can you share any history of how you acquired the car and when? Just curious.

[Carmagic]

I have the car for over 20 years. It needed a lot of rust repair back than. I just built it back than for Autocross racing. It will be viper green.

Here is another thing I did, the transmission tunnel.

When you retrofit a 915 transmission in a 71 911, you need a little more space for the transmission. So when I did this back than, I just used the BFH to make some space. Now, that I rebuilding the 71, I decided to cut out the old transmission tunnel and make a new section and weld in in. Here are some pictures of the progress.

















Cheers
Engelbert

[Carmagic]

I started fitting the rear brake system for the 71 911 project.

Here are some pictures. I use 964 calipers. The rear calipers were modified to fit the rear mounting of the 911 banana arms.



I'm using 930 rear rotors.





I had to modify the dust shield because of the larger diameter of the 930 rotors.





After the brakes for the rear of the 71 911 is all fitted, the calipers were blasted and ready for coating and rebuild.



Here are all pistons cleaned and ready.



I made some plugs to plug the cylinder holes, and used some old brake line ends to plug the line and bleeder holes.





I tried something new and used a heat dissipating ceramic coating.





Brake line complete and ready to bend and install.







I got new SS bolts which holds the guide plates for the brake pads in place, which had to be modified a bit to make space for the thicker rotors.



The bleed valves restored.



Here are the completed calipers.



Cheers
Engelbert

[DMRK]

Totally awesome! You are very skilled, great thread. This kind of work has always scared me. Now I feel inspired by seeing what you have done. Thank you for that. Someday maybe when I run out of projects I will try to build an AWD 914 with a twin turbo W12. OK, probably not but you are truly inspiring.

[Carmagic]

Another small piece of the puzzle, restoring the pedal system.



Back then when I built the car for AX, I just put new brass bushing in and put it back together so it will function. Now is the time to clean it up a bit.



I did some minor repair and grit blasted all the pieces.



I coated the larger pieces with Cerakote black velvet, and zinc plated the small stuff.



There is still some pitting to see in the housing, but I did not want to grind it out, since it would just thin the material.







I'm using Carrera Bilstein front struts for the 71, since they have 3.5" spacing for the caliper mount. I also added the bump steer supports.





Original the struts are green like a John Deer Tractor, but I like to have them Bilstein Yellow. Since I still had some of the correct color powder, I powder coated them yellow.





I also finished some of the other suspension pieces.





Cheers
Engelbert

[blueline]

It all looks so new!! Awesome!

Ok, I'm going barn hunting to find a hidden P hulk for your magic. (Yeah - I picked a section of your un on purpose.) Anyway, I'd hate to see you bored once your current projects are finished, hence the barn search. Hahaha.

Seriously, fantastic work Englebert - it's great for us to be able to see so much of what you do. Thanks for sharing it!

[Carmagic]

A few more things to check off the list.

The front hubs are finished, they are ready for new bearings, etc.





Also finished the spring plates.







Another little project was to restore the front and rear hood locks.





All disassembled and ready to clean up.



Grit blasted and ready for plating.



Finish plated and ready for assembly





All assembled and ready.





Since I will use the fuse box of the later model car, I also started to sort out the wire harness between the dash and fuse box.



Most of the wires I will replace. They are old and some of them are stiff and the insulation is getting brittle.



I made new left and right outer harness for the headlight/blinker. I also added a wire for the DRL included in the LED headlights. Also some of the other wire setups already complete.



Here the inside harness from the fuse box to the headlight/blinker.

Old.



Pretty ugly



The plugs at right is the only piece I will reuse.



Only left to put on new sleeving.



There was only one relay next to the old fuse box for the horn. With the new fuse box I will have space for many relays. I will use the original relay mounts, so I will have relays at the fuse box for horn, low beam, high beam, Oil cooler fan, and whatever else is needed.



Cheers
Engelbert

[Tom]

Love your posts!! You are an inspiration to get out in the garage as I sit here and type.

Can I ask what powder coating oven you have and/or if you made your own? I have an old one from Harbor Freight -- the orange oven long since discontinued -- and it's great for most stuff, but would love to have the extra room I see in your pictures!!