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For what its worth, the Dzus fasteners are similar but not extremely close to the Cup Camloc fasteners.
Very true ... and there are many, many options of Camloc fasteners. It made my head spin working out what were the correct fasteners and receivers and grommets. Very complicated But I think I have sorted it. Thanks Jim for all your help and advice on this journey
I don't want to promise too much at this stage but I have sourced the original camloc pins with bucket handle and the rest of the ex Porsche Motorsport camloc recievers and bevels to suit. I have enough to produce 34 bonnets.
I have drawn up full tech drawings for the original style brackets and found someone who can make up the pressed brackets (this was one of the most difficult parts of the jigsaw!
I have all the dimensions and detail off the original Porsche MotorSport bonnet and am currently getting tech drawings together for a very accurate copy of the underside of the bonnet. There is some work still to be done but I'm hoping the first bonnet will be out of the mould and ready for test fitting by the end of the year.
The intention is for the bonnet to be a slavishly detailed copy of the original, with the same construction methodology, same fibreglass lay up, same dimensions and smae level of finish ... even the same part # on the bonnet underside. The factory bonnets were built to a pretty good standard of finish - substantially better than the currently available glass bonnets that I've seen. They also have a different underside to stock layout to accommodate the recessed bonnet pins and generally save weight.
One deviance from the original may be provision for mounting of stock gas struts as used on the later S2 Firehawk cars in addition to provision for the manual stay as used on the Escort series cars. I am also looking into the use of higher tech resins than were available in the late 80's which offer greater strength and less weight. The original Escort series bonnet that I'm using for dimensions and details is not particularly light. I'd like the final item to be sub 20lb. For the sale of originality and cost I am not minded to look at carbon fibre options at this stage.
I've checked out shipping options and subject to interest I am planning to send 10 bonnets to USA where they will distributed from a warehouse ex Carson CA.
Costs are still to be finalized but to get to achieve the level of detail and finish I'm aiming for is not cheap. I'm guessing the bonnets will be somewhere between $850 - $1000USD ex Carson CA. The hardware package including pins, receivers and brackets is likely to be around $100 - $150USD.
Below is pics of pins that I stumbled upon in a bankrupt stick clearance which started the journey
Respect to you for your efforts trying to reproduce this unobtanium part! I need one to store the real one on my -89 TC. Sign me up for one in that "Europé Group buy"
Respect to you for your efforts trying to reproduce this unobtanium part! I need one to store the real one on my -89 TC. Sign me up for one in that "Europé Group buy"
Kind regards
Peder
Sweden
Hi Peder.
Thanks for the kind words. You are on the list. This wave of enthusiasm will bump the project up the list. Just got to finish clutch, torque tube and LSD project which I'm in the midst of right now.
Thanks for the kind words. You are on the list. This wave of enthusiasm will bump the project up the list. Just got to finish clutch, torque tube and LSD project which I'm in the midst of right now.
Regards Paul
Thanks Paul!
Let me know when the time comes. Maybe I can find interest fom a couple of my countrymen as well if you need to fill the qoute.
Let me know when the time comes. Maybe I can find interest fom a couple of my countrymen as well if you need to fill the qoute.
Regards
Peder
Hi Peder. Looking at the response to date, I think the 34 bonnets I intend to make will be sold pretty quickly. I currently have 2 expressions of interest from Europe. The real benefit of building up the orders from Europe would be to reduce shipping costs. 10 is a cost effective number to sea freight. 5 still works but is a little less cost effective. I think less than 5 would be pretty expensive.
Thanks so much to all have pm'd with messages of support, encouragement and expressions of interest. Amazing response. Not really mentioned this to anyone other than Jim (Oddjob) who has been very generous with his time in helping me with dimensions and specification. Since posting my tentative plans on this thread, 2 days ago, I now have expressions of interest for 11 bonnets. 3 for NZ; 6 for USA and 2 for Europe.
That is 33% of the planned production so is certainly looking viable. At this stage my intention is to limit production to 34 bonnets.
Hi Peder. Looking at the response to date, I think the 34 bonnets I intend to make will be sold pretty quickly. I currently have 2 expressions of interest from Europe. The real benefit of building up the orders from Europe would be to reduce shipping costs. 10 is a cost effective number to sea freight. 5 still works but is a little less cost effective. I think less than 5 would be pretty expensive.
Paul I see what you mean. I will see if I can get someone else from Sweden and I also have contact will fellow TC owners thoughout europe so I will contact them aswell.
Do you have any Idea about shipping for lets say 5 bonnets.
Paul I see what you mean. I will see if I can get someone else from Sweden and I also have contact will fellow TC owners thoughout europe so I will contact them aswell.
Do you have any Idea about shipping for lets say 5 bonnets.
Regards
Peder
Hi Peder. I don't have detailed shipping quotes at this stage other than for Auckland - Los Angeles but Auckland - Germany via Panama Canal shouldn't be that different. I'd have thought shipping 5 units vs 10 units would be no more than an additional $100USD per unit ... so final units $950 - $1100USD landed in warehouse destination in Germany. These are estimates at the moment ... I will firm up on pricing once I get a the first one out of the mould and I have it fitted to my car and am totally happy with it.
Hi Peder. I don't have detailed shipping quotes at this stage other than for Auckland - Los Angeles but Auckland - Germany via Panama Canal shouldn't be that different. I'd have thought shipping 5 units vs 10 units would be no more than an additional $100USD per unit ... so final units $950 - $1100USD landed in warehouse destination in Germany. These are estimates at the moment ... I will firm up on pricing once I get a the first one out of the mould and I have it fitted to my car and am totally happy with it.
09-02-2015, 01:16 AM
But I think I have sorted it. Thanks Jim for all your help and advice on this journey 
