Captain Ahab Jr.

Jack, really enjoying you quest to save weight without compromising comfort

Thanks for posting the weights as you go along, I'm adding them to my list

Have you thought about remove the alumnium bumper girders or would that be a step too far driving around London?

jack.pe

I am thinking about it but don't know much on this subject.. what are the cons of taking them out? does it mean the smallest tap shatters the bumpers?

Rephlex

Of more concern would be that they must form part of the deformable crash structure and a major barrier before the rest of the bodywork is called upon to crumple. If you pass those significant forces straight on to the wings and tub, I wouldn't like to see the shape of the car they cut you out of.

jack.pe

Right, some of you may have seen on my other thread that the engine needs a rebuild. I have spoken to Nick Fulljames and will book the car in for october/november. She smokes a fair bit and is using a lot of oil and the leakdown confirmed it needs doing. As a nice sideline I am going to bring up to RS spec:

-Blue print top end rebuild. Valves, valve guides. Refirb cam housing. Reface heads
-Piston ring ring replacement if the barrels and pistons are serviceable. Cam chains and guides Heavy duty head studs
-Change the big end bearings and the rod bolts
-Cup cams. with an upgrade on the exhaust and remap it should give 300hp plus or minus 5%
Strip and powder coat fan and housing and re-plate hubs and pulleys
GRP trays for around the engine (weight saving)

Will post more on this in a few months

BLACK-BETTY

Awesome stuff

Lemass Automotive

Are you getting the grp trays from roger ? Top chap, he does a lot with nick too and bumper brackets

911Jetta

How much weight, any pics. of these? Do they look golden like the '70's pieces?

PeterS911

Thanks for that, good info to have. I have just ordered new Bridgestones to go on my 17" Carrera 10 spoke wheels to put on my car for our tour of Southern Europe.

I think that combo will be a lot lighter than the 18" Veloces that are currently fitted.

I will put the weights up when I've done it.

Lemass Automotive

They sure do jetta. That yellowed look

911Jetta

^^^^^^ Thanks

The yellow pieces will look great in a blue engine bay. Nice subtle retro touch also.

jack.pe

Not sure on weight, they should lighter, I will weigh them and the originals when the job gets done.. I don't imagine it will be a massive saving but my tinware needs changing in any case.

yes the ones I have seen are sort of gold coloured. And i will go for the fan in yellow.

jack.pe

I did not weigh my veloces when I had them but they felt a hell of a lot heavier than the Cup2s I changed to..

jack.pe

Ok, so I had a look, it is actually possible to fix the spoler in place with tie wraps.. just by putting them between the two upright bars in an upright position, but I wanted something a bit more elegant and that could still be removed. This mod allows most of the motor mechanism (motor, flexi pipe and first gear cog) to be removed. making up a proper bracket and removing the whole lot would be even lighter but I wanted to keep it easily reversible and I'm not sure the gains would be all that great.

I basically just drilled a hole through the swinging bracket and the backing plate and then used a pin that previously help the gas struts in place... it is pretty tight length wise but just fits with the retaining clip in the end. Will rust proof as well.

Drilled the hole, right through to other plate too though not obvious here...



Then insert pin...



And retaining clip..



Fixed in place...



Looks better from some angle than others to be honest... but in my quest for light weight without ruining comfort this is a worth while mod. Will weigh bits when i get the chance. I would guess at around 1kg in all.. not huge but worth while for me..

alexjc4

How cool that the pins from the gas struts were just right to do the job!

I'd be inclined to put a sleeve or bobbin around the pin to keep it from twisting in the holes. Looks like a couple of centimeters gap to pad out, ideally I'd get a bit of 1inch steel bar with exactly the right sized hole drilled down the middle cut to length.

jack.pe

I was thinking of that too, maybe just some hard plastic with a hole drilled through.. just to be safe but it does seem pretty solid even as it is.