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T8
General
General


Joined: 29 Jun 2010
Posts: 13906
Location: Kent


PostPosted: Thu Dec 21, 2017 9:45 am    Post subject: Reply with quote

ELA wrote:


All being well, I am now on track to have this project complete by spring, TUV approved and ready for review Very Happy



Looking forward to seeing it at Dinslaken. thumbsup
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2007 Guards Red 997 Turbo Tiptronic
ex 2004 Polar Silver 996T Tiptronic
ex 2002 Seal Grey 996.2 C4 Tiptronic
ex 1978 Silver 924 Manual
 
  
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Marky911
Barcelona


Joined: 04 Jun 2009
Posts: 1460



PostPosted: Thu Dec 21, 2017 10:01 am    Post subject: Reply with quote

I was just saying to my mate Craig last night that there isn't much car stuff happening at the minute. My cars away, there are no decent bits popping up on eBay and not many good threads popping up....

So it's great to see an update on one of the best 996s out there. Glad you're getting there after the set backs. The parts are looking really good. Cool

Have a great Xmas Rich and hopefully swap the R&D for some R&R. Thumb
 
  
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911munKy
Nürburgring


Joined: 26 Nov 2014
Posts: 399



PostPosted: Thu Dec 21, 2017 12:28 pm    Post subject: Reply with quote

Those suspension components look much beefier (and more gorgeous!) than the initial ones, were the first redesigns just to test the required geometry for the test drives?

This project is awesome, just awesome, thanks again for sharing its progress.
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askgeez
Barcelona


Joined: 05 Apr 2015
Posts: 1327
Location: London/ Essex


PostPosted: Thu Dec 21, 2017 12:56 pm    Post subject: Reply with quote

Well done Rich.
Mechanic
worship
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New997buyer
Yas Marina


Joined: 17 Oct 2010
Posts: 8558



PostPosted: Thu Dec 21, 2017 1:21 pm    Post subject: Reply with quote

Outstanding Mr B worship
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997.1 turbo
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EGTE
Imola


Joined: 06 Jul 2015
Posts: 753



PostPosted: Thu Dec 21, 2017 3:18 pm    Post subject: Reply with quote

Well done for hanging in there, Richard!

Sure it will be fantastic.
 
  
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infrasilver
Fast & Furious
Fast & Furious


Joined: 04 Oct 2010
Posts: 7558
Location: East Midlands

2001 Porsche 996 Targa

PostPosted: Thu Dec 21, 2017 3:34 pm    Post subject: Reply with quote

Glad the gearbox is sorted.
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ELA
Barcelona


Joined: 30 Aug 2011
Posts: 1264
Location: Nurburgring Doorstep


PostPosted: Thu Dec 21, 2017 8:15 pm    Post subject: Reply with quote

Thank you guys, many of you have been there from the start showing your support and offering many great ideas Thumb

Suspension designs have been changed progressively as my car is a development mule. If truth be told I thought my first attempt was perfect and would work just fine however a combination of excess weight or premature fatigue... have meant I've been back to the drawing board more often than I had ever envisaged. I guess that is just part and parcel of taking on something like this.
The main issue is I am trying many new ideas and this induces factors which create problems which you don't consider at conception. Adding 26mm into the length of an LCA for instance, throws up all sorts of issues. This latest design though will be perfect. They have literally just been finished this evening so I will add a few pics of the manufacturing process below.
My apologies is this comes across a bit OTT and I am happy to tone it down a bit if this sort of detail isn't to everyone's taste. I am perhaps just a little sad and a bit too excited with finally having a solution which alleviates all the previous design flaws.
Although these arms are a seriously well designed and overly robust construction for the intended lightweight 911 application, I have gone this route for various reasons:

-All three of the bushes can be replaced if the need ever arises.
-They will offer OEM levels of NVH.
-Extra weight and complexity of design is a compromise in order to achieve greater than OEM durability.

They are a combination of 5 different companies involved to get to this final prototype design. TUV approval to follow Thumb






















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CLR996 1086kg bespoke design


Last edited by ELA on Fri Dec 22, 2017 12:59 pm; edited 2 times in total
 
  
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Dammit
Barcelona


Joined: 23 Sep 2016
Posts: 1365



PostPosted: Thu Dec 21, 2017 8:23 pm    Post subject: Reply with quote

Personally I love the details - more the merrier.
 
  
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NickHappy
Spa-Francorchamps


Joined: 27 Apr 2014
Posts: 367
Location: W.Sussex


PostPosted: Thu Dec 21, 2017 8:48 pm    Post subject: Reply with quote

Amazing work - fascinating to see Thumb
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EGTE
Imola


Joined: 06 Jul 2015
Posts: 753



PostPosted: Thu Dec 21, 2017 9:39 pm    Post subject: Reply with quote

Love those pictures. Thumb Thumb Thumb
 
  
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Johnd52
Nürburgring


Joined: 06 Oct 2014
Posts: 434
Location: North Yorkshire

2011 Porsche Cayman

PostPosted: Thu Dec 21, 2017 10:00 pm    Post subject: Reply with quote

I have absolutely no knowledge or experience of any value to add, but I have been following this from the start and will happily see it through to conclusion. Thanks for posting.
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alex yates
Brands Hatch
Brands Hatch


Joined: 06 Mar 2014
Posts: 13133
Location: The Ribble Valley, Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Thu Dec 21, 2017 10:54 pm    Post subject: Reply with quote

EGTE wrote:
Love those pictures. Thumb Thumb Thumb
worship thumbsup
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ELA
Barcelona


Joined: 30 Aug 2011
Posts: 1264
Location: Nurburgring Doorstep


PostPosted: Fri Dec 22, 2017 4:32 am    Post subject: Reply with quote

alex yates wrote:
EGTE wrote:
Love those pictures. Thumb Thumb Thumb
worship thumbsup

Yep the cameraman certainly has talent Wink
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JS1500
Silverstone


Joined: 12 Apr 2017
Posts: 140
Location: Aberdeen


PostPosted: Sat Dec 23, 2017 9:57 pm    Post subject: Reply with quote

I'm really looking forward to seeing the video reviews of this when it's all set up as you want it.
It'll be a fantastic drive, I'm absolutely positive. Cool
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Y2K
Spa-Francorchamps


Joined: 08 Mar 2016
Posts: 282
Location: Hampshire


PostPosted: Sun Dec 24, 2017 12:14 pm    Post subject: Reply with quote

Great Christmas update Cool
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JohnnyDangerous
Estoril


Joined: 12 Jun 2013
Posts: 3613
Location: East Sussex


PostPosted: Sun Dec 24, 2017 1:21 pm    Post subject: Reply with quote

Nice work Richie
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ELA
Barcelona


Joined: 30 Aug 2011
Posts: 1264
Location: Nurburgring Doorstep


PostPosted: Thu Dec 28, 2017 5:36 pm    Post subject: Reply with quote

I'll be a little busy over the coming days Very Happy



Redesigned LCA's:



Also the castor arms:



Adjustable tie rods:



Easier to fill gearbox before fitting:



Added some trick friction modifier:



Now the job I've been putting off for a while; fitting the GB from the ground. These are unbelievably heavy. So far I've come up with an Egyptian like solution just for sliding it roughly into position but I've not thought about how I'll lift it just yet...



One again thanks for the encouragement guys.
It's great to finally be getting back to it again. Over the coming weeks I'll be looking at modifying the tie rods for weight reduction and making some jigs for the new suspension arms. Ideally if someone has an old hub assembly rotting away I'd be grateful if you could let me know. I would just like to chop one up to make a jig Thumb
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DynoMike
Barcelona


Joined: 25 May 2012
Posts: 1390
Location: The Cotswolds

2003 Porsche 996 Turbo

PostPosted: Thu Dec 28, 2017 9:16 pm    Post subject: Reply with quote

Looking very nice CLR Thumb

Try looking for some motorcycle jack pads to lift the gearbox up into place. There are some scissor lifts available for not much money, though where from eludes me at the moment, which will lift from about 75mm up to easily 350-400. They are just flat pads with an ordinary long screw operation, so easily operated with a ratchet. I will endeavour to find a link to one for you.

In fact, a quick scout around found a better one from wiltec_gmbh on eBay for £78.00. Perfect for you, as it is obviously a German company!

We managed to use one to help install a steel 570 litre air receiver a few weeks back, it lifted that baby with relative ease, so should cope with a gearbox ok.
Your project looks fantastic by the way. thumbsup
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infrasilver
Fast & Furious
Fast & Furious


Joined: 04 Oct 2010
Posts: 7558
Location: East Midlands

2001 Porsche 996 Targa

PostPosted: Thu Dec 28, 2017 10:27 pm    Post subject: Reply with quote

Apologies for the rubbish picture but this is what I made to fit into a trolley jack. Flat plate steel with angle iron sides and tube that I welded on to allow it to slot into the jack. I then use wooden blocks and a strap to hold the gearbox onto the jack, it makes it easy to pull the gearbox away from the engine and then can lower easily in a tight space.



The hardest part is getting the gearbox back onto the jack for installation, as it won't slide under the cra on the jack but a couple of jacks to get it high enough to slide this jack under works fine. Without it, it's like wrestling with a crocodile under a car.
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