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JohnnyDangerous
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Joined: 12 Jun 2013
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Location: East Sussex


PostPosted: Tue Sep 22, 2015 10:15 am    Post subject: Reply with quote

jinjaninja wrote:
Possibly a daft question: are the front and rear impact beams not rather important in the event of an impact??!


Dont crash
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ELA
Barcelona


Joined: 30 Aug 2011
Posts: 1328
Location: Nurburgring Doorstep


PostPosted: Sun Sep 27, 2015 6:22 pm    Post subject: Reply with quote

A few more bits and pieces done today. As I want to work out what level of compromise is acceptable I have decided to remove the insulation/sound-proofing/carpets in stages. Reason being I don’t want to end up with some rattling tin can (race-car). So first I have removed the removable insulation behind the rear side panels and lower panel behind rear screen. Also removed the wiper motor as I have ordered a painted plug to fill the hole.
For info here are the weights I removed (Total today 11.8kg):
Wiper motor assembly (includes insulation behind rear panel): 2.2kg
The 2 carpets behind the rear seats: 6kg
Removable insulation behind rear side panels: 1.8kg per side (3.6kg total)

Whilst there I also weighed a few other components:
Rear side lower panel: 1.6kg
Rear wiper motor cover panel: 0.5kg
1x speaker: 0.6kg
Just to clarify here are pictures for reference:
Rear wiper motor cover (also insulation that I removed):

Wiper motor removed

So this little lot is 2.2kg

2x rear carpets removed, 6.0kg for these; you can also see the 2x sound deadening sheets in this picture (not removed yet):


Rear side panel insulation 1.8kg (I didn’t remove the stuck on material behind the speaker)




The rear side panel is 1.5kg and wiper motor cover 0.5kg:


I aim to cover all the areas where carpets have been removed with lightweight alcantara. I refitted all the panels, so to all intents and purposes it still looks stock. I tested the Hifi at the current stage and there were no perceptible rattles etc. No test drive yet…
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JohnnyDangerous
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PostPosted: Sun Sep 27, 2015 6:26 pm    Post subject: Reply with quote

I know where there are some carbon side panels dude, weigh nothing !!!!! Cool
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ELA
Barcelona


Joined: 30 Aug 2011
Posts: 1328
Location: Nurburgring Doorstep


PostPosted: Sun Sep 27, 2015 6:27 pm    Post subject: Reply with quote

JohnnyDangerous wrote:
jinjaninja wrote:
Possibly a daft question: are the front and rear impact beams not rather important in the event of an impact??!


Dont crash


Not really; they are light alloy so are really only there to prevent serious chassis/engine damage in a light collision. They will not absorb that much force to have any effect in terms of a life threatening crash.
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JohnnyDangerous
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Location: East Sussex


PostPosted: Sun Sep 27, 2015 6:33 pm    Post subject: Reply with quote

ELA wrote:
JohnnyDangerous wrote:
jinjaninja wrote:
Possibly a daft question: are the front and rear impact beams not rather important in the event of an impact??!


Dont crash


Not really; they are light alloy so are really only there to prevent serious chassis/engine damage in a light collision. They will not absorb that much force to have any effect in terms of a life threatening crash.


Exactly that I believe its to stop the bumpers deforming in a 5mph impact.
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ELA
Barcelona


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PostPosted: Sun Sep 27, 2015 6:35 pm    Post subject: Reply with quote

JohnnyDangerous wrote:
I know where there are some carbon side panels dude, weigh nothing !!!!! Cool


But cost a fortune Wink For the likely 1kg max they may save per side I think there may be more cost effective parts to try before getting that serious.
First off I want to see what can be done for free.

After this then (in the following order):
LWFW
Carbon seats
Polycarbonate windows
Carbon roof
Light alloys
Light brakes
Lightweight battery
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JohnnyDangerous
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PostPosted: Sun Sep 27, 2015 6:38 pm    Post subject: Reply with quote

Do you have a sunroof? If not I would not bother with carbon roof, My mate has the panels will prob be cheap, I get a good discount with voltphreaks and on the GT carbon seats if you want it its yours.
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kingston
Suzuka


Joined: 09 Jun 2010
Posts: 1002



PostPosted: Sun Sep 27, 2015 8:37 pm    Post subject: Reply with quote

You do realise that theres a GT3 for sale for £50k dont you on here
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JohnnyDangerous
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PostPosted: Mon Sep 28, 2015 8:32 am    Post subject: Reply with quote

kingston wrote:
You do realise that theres a GT3 for sale for £50k dont you on here


He already has a GT3 Wink
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ELA
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Joined: 30 Aug 2011
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PostPosted: Mon Sep 28, 2015 4:07 pm    Post subject: Reply with quote

JohnnyDangerous wrote:
kingston wrote:
You do realise that theres a GT3 for sale for £50k dont you on here


He already has a GT3 Wink


Kingston, as Johnny says; I already have an GT3, this project is solely for what can be achieved with the Carrera.

JD: My car does indeed have a sunroof hence me looking at the carbon roof option. I'd be very much interested in knowing what sort of prices all these bits are likely cost in the future Thumb

Went for a test drive today and I was quite impressed with the harmonics. I would say only around 5-10% increase in road noise thus far. Based on this I decided to remove the rear sound deadening in the rear. Bit of a pain but a heat gun with plastic scraper does the job. All residue cleaned off with WD40. The 2 small patches came in at 0.8kg.

The real problem is that the surfaces are all undulating with bolts, grommets, channelled grooves... So to lay the alcantara is a bit of a PITA. I decided, as I want as OEM a look as possible, the best option would be to try and level off all the surfaces. So I have been filling in all the channels and removing grommets and re-contouring with Aviation 3M High Speed Tape, re-routing wiring looms... Real time consuming stuff and not helped with the limited space in the back. Anyway getting pretty close to laying the Alcantara now:




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Last edited by ELA on Sun Feb 07, 2016 9:05 pm; edited 1 time in total
 
  
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BenC
Hockenheim


Joined: 01 Oct 2014
Posts: 632
Location: Bucks


PostPosted: Mon Sep 28, 2015 7:18 pm    Post subject: Reply with quote

Glass is surprisingly heavy and high up so worth looking at options there.
I love this kind of thing Smile
I took 250kgs out of my 3 litre '79 SC and it accelerated like a rocket after that Smile
I was being a bit more brutal though!!!!

Also don't forget to thin out any wiring loom and blank switches to removed ancillaries - all adds up !
What about all the plastics around the wheel arches? Don't know how much they protect vulnerable bits or just keep dirt out???
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chriscoates81
Suzuka


Joined: 17 May 2013
Posts: 1112



PostPosted: Tue Sep 29, 2015 6:46 am    Post subject: Reply with quote

BenC wrote:
Glass is surprisingly heavy and high up so worth looking at options there.
I love this kind of thing Smile
I took 250kgs out of my 3 litre '79 SC and it accelerated like a rocket after that Smile
I was being a bit more brutal though!!!!

Also don't forget to thin out any wiring loom and blank switches to removed ancillaries - all adds up !
What about all the plastics around the wheel arches? Don't know how much they protect vulnerable bits or just keep dirt out???


I think wheel arch liners help reduce rust by stopping ***** getting throw up, however if your car rusts away it will definitely weigh less Grin
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JohnnyDangerous
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Joined: 12 Jun 2013
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Location: East Sussex


PostPosted: Tue Sep 29, 2015 7:01 am    Post subject: Reply with quote

Richie !!!!! You went completely the wrong way about removing your sound deadening LOL, you want to freeze it with some sort of plumbing spray and it chips out in great big lumps and doesnt leave that horrible mess on the floor. Hand
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ELA
Barcelona


Joined: 30 Aug 2011
Posts: 1328
Location: Nurburgring Doorstep


PostPosted: Thu Oct 01, 2015 5:50 pm    Post subject: Reply with quote

Johnny, I'd get bored if I did everything the easy way Thumb

Ok as recommended here somewhere I ordered the colour coded plug which arrived today:



Then made a start on the alcantara, real PITA getting this to follow all the contours and sit correctly but the rear section is now done Smile
For info; this only weights 230gr / m2. One of the main objectives is to not dilute things on the usability front, hence all the trouble gone to fitting the Alcantara. If you ask me, it now has a better finish than the stock carpets: the Red leather against Anthracite Alcantara adds a nice balancing contrast, with the added bonus of considerable weight saving




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ELA
Barcelona


Joined: 30 Aug 2011
Posts: 1328
Location: Nurburgring Doorstep


PostPosted: Thu Oct 01, 2015 6:01 pm    Post subject: Reply with quote

BenC wrote:
Glass is surprisingly heavy and high up so worth looking at options there.
I love this kind of thing Smile
I took 250kgs out of my 3 litre '79 SC and it accelerated like a rocket after that Smile
I was being a bit more brutal though!!!!

Also don't forget to thin out any wiring loom and blank switches to removed ancillaries - all adds up !
What about all the plastics around the wheel arches? Don't know how much they protect vulnerable bits or just keep dirt out???


Sounds a beast and 250kg is an incredible achievement Thumb
Glass is something I am defo considering. Probably polycarbonate/Lexan, my only concern is how to stop getting scratches.

I want everything I do here to be completely reversible though, so chasing every last gram from wiring looms etc isn't on the agenda. I will be keeping all the stock interior panels for instance as they are a perfect fit and not particularly heavy (All panels probably only about 7-8kg total) excluding speakers/airbags obviously.
Many thanks for your advice Ben Thumb
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ELA
Barcelona


Joined: 30 Aug 2011
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Location: Nurburgring Doorstep


PostPosted: Fri Oct 02, 2015 6:02 pm    Post subject: Reply with quote

Rear end now complete Smile
I wanted to have access to the suspension top mount bolts so come up with a panel solution which is removable but also something which covers the looms and bolts...
First measured and cut out the panels from 4mm MDF then covered them in Alcantara:





Next up the centre section and voila finally done Smile





About 11.5kg gone with just this rear section
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BenC
Hockenheim


Joined: 01 Oct 2014
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PostPosted: Fri Oct 02, 2015 8:11 pm    Post subject: Reply with quote

nicely done Smile
do you need the rear seats or could you carpet the lot?
how about removing the rear speakers etc?
is there a subwoofer in your car? how about ditch the sub and the rears and just fit better front speakers?
Smile
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ELA
Barcelona


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PostPosted: Mon Oct 05, 2015 6:58 pm    Post subject: Reply with quote

I have calculated that by not chasing every gram and keeping an element of creature comforts 185kg can be removed.
By relative comfort I mean keeping all original interior panels, all four seats and no bare metal.
This 185kg is split 63kg removing components and 122kg by fitting lighter parts (this is a conservative estimate and could be more).

Another 20kg or so is possible by removing all interior panels/carpets/redundant wire looms... This however is not my intention as everything I do I want to be reversible with relative ease as it is still a family car.

Not everything I planned was possible as the central carpets (under the rear seats) have looms and sharp metal edges so alcantara is not possible. I came up with another solution though. Basically by cutting out all the foam it shaves off 2.6kg. It's quite a bit of work for 2.6kg but it has the added benefit of around 5cm of extra head room in the back and still looks completely standard:


Each seat is 23.7kg
centre console 2.4kg
carpet under rear seat 7.4kg (I have now lightened this to 4.8kg)


This picture gives an idea of why you cannot simply lay Alcantara


So instead this is the foam that is removed:


Next up I removed the Passenger airbag, really surprised by how heavy this is at 3.3kg



Then fitted a 2.7ohm resister to prevent airbag warning light illumination




Here is the airbag


And all rebuilt again Smile


So that's it for tonight; so far 42.2kg removed and the car still looks completely OE.

I'll make a weight table later so that others have a guide for future reference Thumb
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BenC
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Joined: 01 Oct 2014
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PostPosted: Mon Oct 05, 2015 7:10 pm    Post subject: Reply with quote

Excellent work on this. I love this kind of project and have been racking my brain trying to think of other things you can get rid of Smile
Presume you've got rid of the spare wheel, if you have one?, in favour of a can of tyre weld etc
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New997buyer
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PostPosted: Mon Oct 05, 2015 7:11 pm    Post subject: Reply with quote

Brilliant! thumbsup

Though does this count as 'What did you buy your 996 this week....?' or do I need to add a post script to that thread, (what did you remove...?) Confused Grin
 
  
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