I parted out a 928 a while back and used a plasma cutter to cut some of the rear body panels off, and it was a bitch. The plastic coating smokes like crazy and I am sure boils off something toxic. I would do it with a die grinder. Better yet, just get s4 rear buckets, drill out the spots up top, cut out the bottoms and splice them in. I think it would be easier to do that, than trying to move the stock 86 buckets up.

Also welding with that undercoating is going to be a pia too, but probably not as bad as a plasma cutter.

 

Hammer,

Sending you a PM.

Martin

 

Thanks for the response.
However, I've never seen the back of an S4 with the bumper cover off. I'd get a better feel for what you're describing if I had. Does anyone have a pic of an S4 with the rear bumper cover off?
Thanks, Hammer

 

I was just going to say that he should contact Louis. I beleive he is just about finished with the molds for left and right side of the car. I will be there Saturday and can let him know you need a set if you are interested.

 

Thanks for the reply dude, but it sounds like you mean in fiberglass. (molds) I only work in metal. Glass is too temporary. Tends to flex & crack the paint. I'm hoping to put a 'better than your average' paint job on it.
Thanks, Hammer

 

I have the glass quarters on my car, with added flares in addition to the GTS "bumps" Gotta make room for the 350s, if I can ever find any. I would think you save some weight going with fiberglass, if you give a hoot about weight..I didn't weigh the old ones as they came off, but I recall they are the only steel on the bodywork (probably steel to add weight to the back to balance the cars better?) Mine look like they grew there. I've seen Louie's "work in progress" with his "GTS-style" flares over his GTs body. The job is getting the second part to match the first. You can't just turn the mould inside out, you have to make the other one, too, and matching it to the first is quite tedious, says Louis. One other thing you might consider, if applicable to your model year, is to move the fuel lines to a safer place while you have the quarters off. They run in the wheel well right behind the passenger door pillar and I have seen them hanging out and bent by relativly light contact. They are also vunerable to rocks and debris, if for any reason your fender liners should be breached.
Don Hanson

 

i had my rear 1/4 updated to GTS following an insurance claim too! the quarter panels are comparitavely straight forward, but take time. we didnt remove the entire panel but placed cuts acording to the WSM which saves removing all the spot welds over the rear windows. you will need a new fuel flap as mentioned.

sounds like updating the rear cover is more involved?? i think carl at 928 motorsports has some flared arches too, if anyone is looking!

 

The killer foam is in the b pillar the cuts you will be making are all single layer of sheet metal. The rear inner panel from the outer 1/4 flange to the main body has to be heavily modified for the lights and the main rear cross panel needs holes cut maybe seven inches by 5 inches for the bumper cover lights to fit.

 

yes, they did some quick cutting and bending. nothing in the back there fits very well. the car even had one rear quarter panel removed and replaced from one of the on track safety car accidents. (in fact, both front fenders are replacements too!) the one rear quarterpanel has the parking light hole filled in with bondo, as the Holbert car had no parking lights front or rear on the fenders.

MK

 

nice wheels mark! and i like the rear spoiler extensions also. what kind of chin splitter is that?

 

thanks. I like those Kinesis too! (K-18s) 18"

the rear wing extentions were shaped from composite foam plastic and stacked up. (very light but strong) and extra long bolts were added. wing is 3" higher than stock, plus a 10 degree tilt

the front splitter is a GT3 cup car splitter, that was given to me by Don hanson who modified it to fit his car. not a perfect fit, but it looks ok.

MK

 

Thanks go to Don Hanson who visited this week and gave me some tips on how to better match the 2nd side to the first. Any way you do it, the job is very tedious. It is progressing and I might have the proper contour shaped on the 2nd side in a day or two. You have to admire those who take on reworking nearly the whole car like "Fat Bully". I'd be too old to drive when I finished if I tried that. I'll post some updated pics on my web site, www.performance928.com, Tech talk page, of the contour template arrangement I made. Learning to work with clay rather than "Bondo" has been an interesting challenge too. Then all I have to do is put a finish on the clay, add flanges all around, pull a female mold from the plug, rework the mold I already have for the first side to incorporate some changes I made, and make some trial parts. My original time estimate to have parts I could use has slipped from mid July to maybe Halloween. That's about normal.