I'm sure you've been busy... But I, for one, am super excited to see the countdown resume. I check this thread daily for updates. Sail on Captain!

 

Definitely one of the most interesting thread and intriguing character on here :-)

 

Agreed this is an epic and it's only just begun

Picked these up from. Guy who makes the calipers and rotors for a few of the one make / specified series here and in Oz

..made to my specs based on the Zimmerman drilled RS spec rotors I had on the car .... But that is to the Ali hats and thinner vanes the results are a couple kg lighter per corner ... Ahab do you subscribe to the 4x idea for the impact of unsparing weight vs sprung?

Pretty bits require pics! Billet especially!

 

j thanks for following my random posts and apologies for the slow build pace, I have a lot of projects waiting in line and little free time.

Here is my summer project, zombie proofing my garden, will finish it up end of Sept. and over the winter plan to get stuck into my car. Oh and there is also the small matter of finding a new job.





thanks breljohn, been called lots of things before, never been called intriguing, hope we don't meet in person as I wouldn't want my reality to disappoint you

wow HiWind, beautiful, brake eye candy, they look fantastic and 6 pot's too, a much more inspired choice than the big red route

I've discussed the unsprung vs sprung question with car handling experts (not mechanics but cone heads, real clever computer simulation whizz kids) and read everything I can find on the internet.

Lots of numbers out there but I think it is impossible to pick one as it really depends where the weight is removed on the unsprung parts of the car. 1kg from the tyre will have a much larger affect that 1kg from the wheel carrier due to rotational inertia.

Unsprung is one area of my car I will really concentrate on for removing weight, I spec'd my brake calipers so I can upgrade to PCCB disc's one day when they are affordable, until then I will have cast iron disc's with aluminium tophats, same as yours. I have gone small on my brake set up as I'm hopinbg to ducting enough cooling air to keep everything happy.

 

Nice garden Capt. Are you close to Stowe?

I hope your projects inc the job hunt go well - patience is usually rewarded

Re the cooling - I especially like the j curve slotting on those discs and the directional vanes ... He also says the flex in the billet calipers (which I haven't bought as I refinished mine) is much less than the cast ones hence their value add.

But the discs are 40% cheaper than OEM and I run them on my 05 cup where they are still strong after 2 seasons so I'm convinced they'll do the job. Running blue stuff EBC pads from your fair shores for the first time ... will update my dev journal once tested.

 

Indeed I very much look forward to seeing how this build progresses. A lot of innovative ideas and thought.

 

HiWind, good spot on the local stone colour, I am about 20mins north of Stow

Frank, thanks for the , I'm just as much enjoying watching your stable expand

been away and found 2 sets of these waiting for me.....

Titanium Profi II-6 are the lightest weight off the shelf seat belts I could find, 1.558kg a set, metal latch plates are titanium and titanium nitride coated for a bit of extra gold sparkle



took a lot of umming and ahhing to convince myself the 1.5kg weight saving over normal 6 point belts was worth the extra but now having them in my hand and seeing the quality and finish I'm so glad I over spent

just for comparison a set of F1 seat belts weigh in around 0.5kg

 

Finished my summer project which mean I can finally have some Porsche time to myself, I think 2ft thick should keep out even the most determined tank driving zombie. Well pleased with the end result considering it is our first time building a wall.

My handy work


Mrs Ahab's handy work, it the neater face and our side too, what a doll she is



Nearly got a job, I've gone brave and setting out alone to work as a freelance motorsport contract design engineer/consultant. Exciting times at the moment as it looks like I might be lucky enough to get to choose between a few exciting projects for my first gig.

Getting back to why I created this thread, I've sorted out my winter 964 job list, should keep me busy enough...

Make some ramps so I can easily corner weight the car to keep tabs on the weight loss.First weigh in will be no fuel to give me an up to date baseline
Strip back redundant wiring/connectors and rewrapped loom, a nice cheap job
Fit my interim lightweight wheels and new rear tyres
6 speed gearbox and gear linkage (maybe lightweight starter motor and flywheel, will see when I'm in there). Any suggestions of where to buy a lightweight flywheel in the UK?
Sunroof delete, going for a carbon bond in infill piece
ABS delete
Power steering delete and maybe commission the machining up of an RS ratio rack and pinion depending on costs and if I like the feel of unassisted steering
Cat delete and cut off the heat exchangers from the stock exhaust headers
Starting the process needed to make a carbon front mounted oil tank

Not sure if it will all get done and where it will put my weight total but I'll post up progress and I'll be disappointed if my total of weight removed is below 225kgs by the time I get to the end of this list.

 

who made you those calipers?

 

For the slow ones at the back and anyone who has recently stumbled across this thread here is a quick recap on my weight loss efforts with my car

10g Carrera 2 rear badge
2497g rear wiper assy (wiring still to be removed)
9018g stereo system including centre tunnel tape holder and a Del Amitri cassette tape left by the PO (wiring and radio metal chassis still to be removed)
212g pair of alumnium carpet edging cover strips
797g pair of sun visors
3614g rear parcel shelf
1877g front footwell carpet mats and brackets
576g pair of front corner carpet trip covering heating ducting
342g pair of engine lid gas struts, mtg pins and clips
702g fuel tank plastic protection shroud
98g wire plastic shroud under VIN in front trunk
189g ABS unit plastic shroud
24g wire plastic shroud between battery and front bulkhead
37g fuel cap flexible flap cover
2669g engine bay heater fan unti, ducting, mtg bolts
1631g engine bay sound deadening
1888g heater flaps, jubilee clips and donkey dick to heat exchanger
1947g metal tubes and jubilee clips from heat exchanger to engine bay tin
708g various engine under tray mounting brackets
89g spoiler mechanism plastic shroud
0.414kg interior trim cappings below side rear windows
3.305kg rear bulkhead internal sound deadening (car louder but not annoyingly so but this may change when I remove the rear seats)
2.425kg interior rear wheel arch trim
0.615kg inner door sill carpets
0.727kg drivers footwell carpet
0.141kg carpet behind pedals
0.672kg front passenger floor carpet
2.204kg front passenger floor sound deadening
0.279kg heating donkey dick from dash to cill inc. jubilee clips, pair
0.106kg plastic sill vents below rear side window, pair
1.961kg heating donkey dick insulated ducting inside the cill, pair
5.100kg rear bumper aluminium beam (not inc. fixings)
0.800kg rear bumper beam mounting tubes, pair (not inc. fixings)
4.700kg engine under tray (not inc. fixings)
0.258kg set of 4 wheel centre caps (not orginal Porsche parts)
1.550kg passenger seat electrical motors, drive cables, wiring loom and steel mounting bracket
0.024kg cigarette lighter
0.285kg ashtray and dash holder
0.895kg pair of rear floor carpets
0.055kg diagnostic plug steel mounting bracket
9.332kg rear seat area and rear foor sound deadening (not including rear bullkhead area)
0.220kg carpet behind rear sear bases
0.609kg pair of carpets outboard of rear seat bases
0.232kg pair of carpets below and forward of rear seat bases
1.171kg pair of leather seat bases
6.170kg pair of leather seat backs including outboard bolt (not including centre sprung pin bracket, will add this to the weight as I forgot)
0.742kg sunroof air defelector, front sunroof metal surround
0.182kg plastuc outer sill protectors
2.098kg pair of rear seatblets including mounting bolts/washers
0.142kg drivers footwell battery cable shroud
0.449kg sunroof motor cover panels
0.768kg central tunnel carpet (not completely removed)
3.229kg central tunnel sound deadening (not completely removed)
0.156kg pair of rear seat locking pins
1.548kg drivers seat electric motors, cables and steel cross member
0.044kg leather swatch sample under the drivers seat
1.500kg drivers floor pan sound deadening
0.087kg B-pillar vinyl trim
0.935kg radio chassis and some wiring
0.318kg bitumen sound deadening strip on central tunnel LHS
0.108kg spare wheel clamp and bolt
0.113kg ABS pump plastic cover
1.682kg alumnium jack
0.471kg kack handle
0.601kg wheel brace
13.487kg spare wheel
1.973kg tool roll
0.135kg steel battery cable shroud under the spare wheel
0.770kg sunroof motor and mounting bracket
0.273kg bitumen sound deadening strip on central tunnel RHS
0.681kg bitumen sound deadening on rear floor behind front seats, pair
1.976kg sound deadening under dash and front wheel arch area (still some left behind the pedals)
0.708kg plywood pedal board
1.2kg tyre pump kit
1.169kg pair of door pocket lids
1.875kg pair of door pockets
0.423kg pair of door speaker wiring mystery junction boxes
0.042kg Porsche bonnet badge
0.916kg glove box lid
0.976kg steel ECU tray inder passenger seat
0.049kg plastic bracket under brake fluid reservoir (really not sure why this is fitted)
0.355kg more stereo wiring
0.044kg brake and clutch pedal rubber pads
0.445kg HVAC unitl plastic shroud and bonnet rubber seal
2.791kg alarm boxes, immobiliser, wiring and sensors
4.024kg pair of interior door panels and door interior handles
1.159kg pair of interior door tops
0.351kg pair of bonnet gas struts
0.093kg under dash HVAC duct, rhs above drivers feet
10kg cup bypass exhaust pipe (rounded down as removed by previous owner)
0.040kg bonnet light
0.064kg steel electric connector bracket in front of RHS bonnet hinge
0.095kg HVAC duct LHS dash corner
0.109kg HVAC duct diffuser above passengers feet
0.082kg HVAC duct diffuser above drivers feet
0.067kg steel electrical box bracket above passengers feet
0.339kg pair of door central locking solenoids
1.730kg extra windscreen and headlight washer reservoir and piping under the front wing
0.861kg front suspension/steering undertray
0.129kg centre tunnel interior handbrake tray
0.378kg pair of air deflectors for front brakes (one was already missing and it made no difference)
0.030kg radiator bracket that served no purpose
1.870kg centre tunnel floor steel cover plate
0.495kg centre tunnel forward interior trim cover panel
0.302kg steel loom/relay bracket under above trim panel
0.779kg centre tunnel, pedal and RHS front wheel arch sound deadening
0.050kg more radio wiring
0.119kg pair of interior roof courtesy lights
0.095kg headlight beam vacuum adjustment tubing and switch (still have headlight diaphram actuators to remove)
0.120kg HVAC duct through bulkhead on RHS side
0.115kg HVAC duct through bulkhead on LHS side
0.510kg roof lining and roof sound deadening (not inc. sun roof lining, A, B or C pillar covering, just the roof lining)
0.037kg spot welded steel spare tyre mounting bracket
0.075kg spot welded steel bracket under RHS front chassis leg
0.025kg B pillar coat hooks, pair
0.005kg metal self adhesive spare tyre inflation instructions label
0.866kg bitumen door sound deadening, pair
0.110kg trim, sound deadening and carpet at the base of A-pillar
0.302kg pair of steel flanges at the base of the B-pillar
0.120kg bonnet slam panel plastic cover
0.012kg pair of plastic pop-riveted brackets under bonnet slam panel
0.987kg HVAC control unit (non-aircon spec.)
0.691kg HVAC heat sink
8.537kg HVAC unit, inc. wiring loom, ducting to bulkhead and drain tubes (non-aircon spec.)
1.555kg front fuse box bulkhead section cut off leaving only the fuse box housing
0.064kg pair heated windscreen washer jets wiring leads
0.161kg excess washer jet tubing after deleting the underwing washer bottle
0.852kg front cat heatshield
1.087kg cat lower aero sheet steel cover
2.50kg pair of front wheel arch liners including fixings
0.368kg LH rear plastic lower engine shroud and fixings
0.352kg RH rear plastic lower engine shroud and fixings
0.582kg RH plastic lower engine shroud and fixings
0.444kg pair of bumper mounting to chassis rail reinforcing steel tubes
0.025kg rear under tray steel mounting bracket (forward engine position)
0.102kg radio chassis steel surround
0.219kg pair of HVAC dash vents, ones nearest the doors
5.062kg front aluminium bumper beam and mounting bolts
0.917kg front bumper steel mounting tubes, mounting bolts and gaskets
0.388kg large horn and steel mounting bracket (a bracket on a bracket )
0.349kg steel mounting bracket for horns
0.050kg foam front bumper in fill pieces
0.246kg headlight washer nozzles and tubing in the front bumper
0.387kg LH dash knee pad
0.406kg RH dash knee pad
1.09kg front fog light delete, pair (thank you previous owner)
0.156kg sunroof drain tubes (2 front and 2 rear)
0.195kg spot welded brackets from rear seat area (not incl. large rear seat central pivot bracket and seat belt inertia mounting brackets)
0.206kg C pillar roof interior trim
0.772kg pair of steel front brake disc shields
0.234kg pair of aluminium rear brake disc shields
0.211kg rear bumper centre section lower edge steel strip
0.268kg sunroof wiring loom from motor to rear bulkhead connector
0.253kg pair of door window inner felt seals
0.115kg spot welded steel rear seat centre pivot bracket
0.223kg internal door lock rotary **** and linkage to door latch

I have yet to add any lightness but this will come later when I have run out of parts to remove

Today after a long absence I launched into the wiring loom starting simple with the passenger door loom. I only chased the wires back to the plug in terminal under the dash near the A-Pillar, will remove beyond this another day. I just kept the electric window wiring and this is the pile I didn't want to keep



0.360g passenger door mirror and central locking wiring loom

weight removed running 174.638kg or 385lbs

 

so when are the seats coming out and what will replace them?
That'll bump you through 200 kg easy ...
oh and I think it's time for some pics of what the car looks like, no?

and didn't you replace the cover under the steel fuel pump cover plate and replace it with CF?
(yes I still want one edit: oops found that it was RobT - saved a few grams too ie 458g vs 120g)

 

Just for grins I added up all the weight of the items you removed that were less than 300 grams. People often discount the returns on small weight savings, thinking a few grams here and there won't make a difference.

You've removed a total of 64 items that weigh less than 300 grams, for a weight savings of 7.744kg for those small parts! Roughly the same weight savings as removing the front aluminum bumper and rear wiper assembly combined. That's about 100 more meals worth of pizza and burgers you can eat without worrying about the weight gain

Ounces really do make pounds.

 

Hi HiWind, seats will for sure come out, not sure when but I'll replace them with something custom and lightweight. I have a few neat ideas which I will leave for when I get around to them.

No, not made a carbon fuel cover, still got the steel part fitted.

I have some lightweight wheels I want to fit, will take some pic's then but be prepared to be underwhelmed as my car is not the prettiest

Hi jstyer, well spotted you have nailed what so many people fail to see or discount as not worth the effort, I like to work in grams as eventually as they make kgs which are heavier than lbs.

Forgot to mention my wall building lightened me by 6kgs, all useful weight high up

 

Don't overlook a diet for the driver......

 

now we are talking in lbs and kgs