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Widowmaker Project - Building a GT2 Clone

Old 10-16-2018, 03:37 PM
  #31  
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Originally Posted by RallyBird View Post
Awesome build. I haven't driven my car in about a week and now I'm deing to go for a drive after reading this.
Thanks for the complements! Glad to inspire you to get out and enjoy a fun drive!

Where do the weekends go? Projects always seem to take at least two to three times longer when people stop by the garage to chat or needing some quick advice. This weekend was more about wrapping up a lot of little things to get some major things done before the snow flies. The big plans were to move some things around the garage to better utilize the space, the main focus would be on the area between the lift and the stairs into the attic which still was being under utilized.

This area bugged the hell out of me as it was not large enough to either put a lift or even just a car due to how it ended up being laid out. The front part of the garage I had originally placed the Bridgeport and Lathe as it was close to the main breakers. However this is the higher traffic area when moving cars in and out, it offered a much more usable space to say park projects that are not being worked on or the cars that are regularly being driven.

First thing was to move all the little things that had gravitated this area and since neither the mill or lathe were being used yet, they had become a bit of a flat-ish surface to store things. Once things were cleared out, the bridgeport moved out of the way first.



The next step I laid out where the lathe was going to sit and marked with painters tape.


Then the easy part of lifting up the lathe and putting it into position.....now if I could only find those 4x4's that I used as dunnage. The moral of this story is not to use all your for summer evening camp fires Lucky for me I found 3ft left over behind a lot of other stored building materials. Of course the saw was up in the attic from that entire project so this was like continual challenges of a poorly organized plan.

Once I cut up a couple 10" sections to go under the casting to prevent the forks damaging the sheet metal I was able to get the lathe up in the air.



Next was to move the bridgeport into position, which lucky for me resulted in not much clearance to sneak the fork truck back out Good thing I had not started with the baseplate extensions for the lift otherwise it would not have fit. But more on that later.



Then a local 928 owner stopped by needing some insight on how to wire up some 996 seats into his 928. He made the brackets and got the passenger seat installed without issue.


However the driver seat on a 996 with power and memory is a bit harder to do. So we pulled the computer box off and then compared to the 996 wiring in the Turbo to figure out how to fool the key signal. About an hour later he was back on the road and I was able to turn my attention to the wiring of the machines.


My old man stopped by to lend a hand, in another life he spent it doing lots of machine wiring controls, we were able to get the lathe and mill up and running. Now time to chase down some other tooling for work holding. Ordered up some new R8 collets and a power draw bar setup for the bridgeport.

https://imgur.com/SfLcRHX https://imgur.com/hDNbdEV Next battle was a free broken spring compressor that had been left outside for several months until offered to me. So of course it was rusted solid, mind you I have been spraying it with some Kroil every week for several months, so with a little more Kroil and some heat it freed up. Note fork trucks work great as a work surface as they do not move around when you need to put some good old fashion brute force to something.

https://imgur.com/kjdRZeL Being that the mill and lathe were stored for several years, there is some surface rust that will have to be dealt with, no big deal with some soft 3m pads and WD40.




Up next for these is to drain the oil out of the lathe gear boxes and replace with fresh oil, make sure the DRO's are calibrated and should be good to cut some chips!

Look at all that space!


The base plate lifts have always bugged me from not having a cross support overhead to prevent the lifts from pulling in. As an additional safety increase, I picked up some extensions to bolt to the base plates that increase the amount of lag bolts you can put in. While my intention is to get to making my own cross brace at some point in the near future, it could be several months until that happens so might as well just install these.

Of course my hammer drill had been borrowed by my old man doing his house project, so another hour and a half trip to go get that to wrap it up late Sunday night.




Moral of the story, even with setbacks you can still manage to make good progress in two days. While more things crossed off the "pre-winter to-do list" would have been nice, some small victories are good enough to warrant a glass or two of whiskey at the end of the day.
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Old 10-16-2018, 05:59 PM
  #32  
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Sweet.
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Old 10-16-2018, 06:03 PM
  #33  
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nice!!!!
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Old 10-17-2018, 04:55 PM
  #34  
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Great thread, thank you for sharing.
Where did you source aluminum carrier? Have a part number you can share?
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Old 10-17-2018, 05:51 PM
  #35  
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Originally Posted by Carlo_Carrera View Post
Sweet.
Originally Posted by Medevack1 View Post
nice!!!!
Thanks guys!

Originally Posted by ms4cd View Post
Great thread, thank you for sharing.
Where did you source aluminum carrier? Have a part number you can share?
Per powdrhound's thread https://rennlist.com/forums/996-turb...ight-loss.html

997.331.261.02

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Old 10-29-2018, 07:00 PM
  #36  
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The other night my buddy who owns the 308 stopped by as well as U-928 to look over the 308, the car needed some love from sitting and why not another winter project for us to tinker on....I might regret this hand built by Italians in a dimly lit garage type project. So far it looks like motor out, belts, all rubber bushings, some exhaust work, carbs, fuel lines, suspension/brakes/bearing overhaul, shall see how much he really wants to dig into this.




The 308 project to be continued....

I have been on a bit of a hunt for a little band saw as I sold the big monster one that took up the space of a car, no need for a big production saw for a hobby garage. Found this one last week on the book face and planned a trip after work on Thursday to pick it up.

Some times things go sideways with well laid plans, I noticed on the ride into work that the truck was a little louder than usual but did not think much of it as it is getting a new drivers side manifold next week because of a leak. Firing it up to leave it was loud as all hell, poking my head in the fender liner I could see fire coming out of the manifold that was replaced two years ago. The manifold split at the casting line as well as in another area. Driving two and a half hours with a blown apart manifold was going to be asking for trouble, do a quick call around I was able to find a truck to borrow for the night and run down and pick up the saw. Now I cannot wait to get that manifold off and see what the hell went wrong with it.

Yay! Now we can cut all the things!


Made a little progress inside when the sun goes down and being sick and tired of outside cleaning duties. Using the new saw I was able to make quick work of shortening the draw bar for the power draw bar setup. Then some quick plumbing of air to it made for a solid moment of progress.



The other project was to paint one of the inside doors, did ran out of time and energy to finish up the wall section around it. That will be later this week. The Colorado Gray is a nice classic color for the doors in the garage....of course the other half keeps referencing it as the blue door...hmm




This weekend involved some other projects at first on my old mans barn. With the snow coming shortly he was is a mad rush to get the stalls up so the horses can get in from the cold/snow/rain. The lift point for doing hay needed some strength added to the 8x8 so I welded up this bracket to tie it into the other cross beam. Last time I left it to him welding something up he welded the gas cup and tungsten together and left the garage saying I broke the welder.....Ah those bonding experiences with a slightly cantankerous father




Note the choice of hammer as he is in the normal rush mode of getting things done. No point in going back down and up to find other tools.


Not too shabby


Since I owed him one for helping with the wiring of the lathe and Bridgeport a couple weeks ago, I offered my Saturday up to help build the stalls for the horses. Moral of the story I think he got the better deal as I still ache from lifting the grates up into the walls.

Got the first one up in enough time so his wife could stain it, then moved onto the other two which of course seemed to take no time compared to the first.





Of course this little terror kept taking any writing utensil I left sitting by the saw as cutting lumber.....


Wet, cold and tired we called it a day. So Sunday it was time to stay indoors in a warm garage as I had enough of lugging lumber in from the rain in a cold windy barn.

With the lathe and mill setup, my attention was on the fact that over the past year I have grown a bit tired of playing car shuffle as the three main spots sat right behind the two-post lift. The mid rise lift was at an angle that made it easy to use, but with the Corrado being the main fixture to reside on it, the use of the space was not perfect yet.

First thing first was to move the mid rise deeper into the garage but in a place that still offered good use of it and closer to the tools. This would free up the right side of the garage to allow cars to be pulled in and out of the way keeping the main shot to the lift open or when winter storms come in, the area can be packed with the daily/plow.

To gain space the welding area needed a revamp. This also ended up making extra use of the wall for hanging things off and also allows the welders to easily reach the two lifts.


Next was to clear all of the stuff that had managed to find its way around the Corrado, mostly the collection of parts that need to make their way back onto the car. After that I decided to set the rough alignment so the car could easily roll without the use of dollies.



Enough with distractions of working on a car....need to keep moving! The next thing was to move the lift off the steel plate then move the steel plate that the lift rides on over to its new home, well home until it is decided it needs to move to a better location.....


With the Corrado back up on the lift....needing to come back off once again so the back of the lift can be scooted ~8-12" to the right to make a little better clearance for cars going onto the two post. I turned attention to painting the block plates for the AC's that will have to come out, as well as painting the far wall by the blue....caugh... I mean gray door.


Time to call that a wrap, oh wait some seating is required and perhaps a beverage to sit back and relax the days work. With the old 996 seats gone the Corrado ones work perfectly for the time.


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Old 12-03-2018, 11:43 AM
  #37  
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Was able to meet up with Marcus this weekend and pick of my set of Manthey doors, totally blown away with the quality of these! Time to send these and the hood off for paint shortly!







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Old 12-06-2018, 07:17 PM
  #38  
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Those doors are awesome. Eventually Im going to have to pick up a pair for myself.

Are you using OEM GT2 bumper?
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Old 12-06-2018, 09:26 PM
  #39  
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Yeah Chris well worth picking up the doors! As for the bumper it is an OEM one with all the OEM ducting. The decklid is not an OEM one but came from some company in Germany, rather than going adjustable OEM this works well as I just machined up some additional shims at 3░ increased attack angle if needed.

The big debate I have been thinking about is if I want to ditch the A/C on the car. I never use it, but perhaps if I am caught on rainy days I would want it to keep the girlfriend happy.
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Old 01-03-2019, 03:05 PM
  #40  
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Have not spent any time working on the 996 as the main project of getting the Corrado running has taken number 1 priority, with the 996 engine drop being up next. Progress has been slow, but at least moving forward in a reasonable manner for the fact that the car has been apart for nearly 10 years. Projects like this always seem to suffer the multiple catch-22 scenerio's where either a missing part or something else needs to be dealt with prior to allowing the current path to continue.

Current snags are :
Waiting on new baffled oil pan/cast thermostat housing so rad support has to stay off for now.
Discovered I misplaced or lost my wideband side of the harness for the MS3...so a new one had to be ordered.
Waiting on potential Non-AC blower box to show up from Europe...no word yet so waiting to put dash back in.
Needed to figure out a what to run the PCV....materials had to be ordered.
Need to make brake booster Vacuum line that fits the Schimmel manifold...materials ordered.
Started to make the Oil Cooler Lines....in order to save hours of time ordered assembly tool for Push Lock Hoses
Lost or misplaced fan switch so had to chase one of those down.

It was not in my practice back when starting to put the Corrado back together to mark torqued/tightened hardware with witness marks. So I have adopted the strategy of every time I have say a 13mm or 17mm out, I tighten every one or check them then mark them accordingly. This is something I adopted during all the years of track days having things apart and back together that some times might be apart for a couple weeks, not wanting to overload my memory I got into this habit. The sister TT that I sold last year had lunched a motor due to a shoddy repair done on the tensioner threads, which resulted in me taking just about everything apart and assembling a complete new drivetrain for it over several months, the good news was in so marking and checking every nut and bolt, there was not a thing that needed attention once the car was back together.

I get this from McMaster-Carr and use white for tightened. Red for things that are Red Loctite, Blue for Blue Loctite and bright neon orange/yellow for suspension things that like to work loose on the track.




Finished assembling up the revision of the fan shroud setup that has mounting for the relays as well as mount holes for ducting.


This fire wall heat shield needs some love. A good cleaning will be needed perhaps in the hot tank at work.


After some digging around it appears that this MK2 rain tray will work perfect rather than the little piece that just covers the vent normally on the Corrado's. Some small trimming looks to be needed but should do the trick.



Cleaning old connectors and re-wrapping the harness with techflex has been the better part of the past two weeks free time.


Nice and clean





Tons of freshly plated hardware.


Setting up the oil cooler and push lock lines. Normally I do the WD40/hot water trick to finally get it to go all the way onto the barbs. If you have ever experienced this, to do 4 connections beats the hell out of your wrists/palms and generally takes hours to do. Having done it several times on for both of the Audi TT's by hand, I finally decided I would just roughly get them on and then order the tool. Being that the 996 will be getting some cooler upgrades ~8 new connections for the GT2 cooling, saving countless hours seems the best way to go.




A little trick for getting the firewall boots for the harness to seat without uttering every curse known to man, is to put a little WD40 on the seat of the boot and they will slip right in.

And so she sits until the next round this week. Which looks to be removing the seat heater circuit and auto seat belt wiring. The attempt is to get the Corrado back to running state with perhaps some final finish work needed so at least it is road worthy. Then can focus on the 996 to do the coolant fittings and GT2 Slave, Evoms Inlets, diff and Kevins single mass flywheel setup.
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Old 01-10-2019, 10:08 AM
  #41  
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You call this a 'Hobby' garage, I think many would call this a realistic dream garage... I mean seriously, who else here has a lathe and bridgeport in their personal garage???

Super awesome and jealous!
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Old 01-10-2019, 12:27 PM
  #42  
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Originally Posted by NoogaSparrow View Post
You call this a 'Hobby' garage, I think many would call this a realistic dream garage... I mean seriously, who else here has a lathe and bridgeport in their personal garage???

Super awesome and jealous!
Thanks Nooga! Having the tools and space does make the ownership a much easier proposition, granted space is the biggest constraint in most times, many years of collecting stuff here and there. It is still an evolving DIY garage with the next plan to build a paint booth.
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Old 01-10-2019, 07:51 PM
  #43  
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Those look like SSRs ... reminds me of my Sirocco, makes me miss my Sirocco...
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Old 01-11-2019, 11:05 AM
  #44  
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Originally Posted by 2fcknfst View Post
Those look like SSRs ... reminds me of my Sirocco, makes me miss my Sirocco...
Good eye! While not the most pretty wheel, at 11.4lbs they do the trick! MK1 or MK2 Rocco?
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Old 01-11-2019, 03:01 PM
  #45  
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Originally Posted by TheDeckMan View Post
Good eye! While not the most pretty wheel, at 11.4lbs they do the trick! MK1 or MK2 Rocco?
Thanks, I have a set on my 2004 WRX STi, and the 'Rocco was a MK1 - 2.0l Huron head, Schrick cam, Bilstein BTS kit, etc etc etc... good times, as I recall...
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