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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Wed Oct 10, 2018 6:54 pm    Post subject: Reply with quote

So after waiting for over two months for my exhaust rings to be made and then turning up the wrong size I started to get a bit p'd off. Before putting them back in the post to James I took a few measurements for him so he could get them made to the right size but this just got me thinking surely I can make these out of stainless tube. So a quick look on ebay and I had the right diameter tube 63.5mm and the right 2mm thickness in the post to me for about £8. The plan was to take the tube and grind down the sides to create the right profile.
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997.1 C4S CAB

The Finn's 997 4S progress thread take two
 



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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Wed Oct 10, 2018 6:57 pm    Post subject: Reply with quote

To get the right size and shape I just cut the tube to the correct width and then to shape it I just ran the saw using the blade to grind down the edges to give the eliptical shape. A set of old mo0le grip spared my fingers
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997.1 C4S CAB

The Finn's 997 4S progress thread take two
 



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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Wed Oct 10, 2018 6:58 pm    Post subject: Reply with quote

It only took about 1 hour if that to get them to the correct shape
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997.1 C4S CAB

The Finn's 997 4S progress thread take two
 



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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Wed Oct 10, 2018 7:01 pm    Post subject: Reply with quote

Now I was going to get my dremel out to put the groves in that grip against the tip clamps and do a tidy job with straight lines etc. But could I find the right size shank for the dremel blade no so I thought 5od it I will just use the chop saw as at the end of the day the groves are just for grip so that's what I did.
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997.1 C4S CAB

The Finn's 997 4S progress thread take two
 



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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Wed Oct 10, 2018 7:05 pm    Post subject: Reply with quote

Now I wasn't sure that groves I had made would work but I thought I could always make another set so it was worth a go with the untidy method. The rings got sliced as per the originals and this photo shows the profile against the nd ones.
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997.1 C4S CAB

The Finn's 997 4S progress thread take two
 



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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Wed Oct 10, 2018 7:10 pm    Post subject: Reply with quote

These then got pushed into the tips and fitted to the car. I will have to post up a final shot later as one of the old brackets on the tips snapped when I went a bit OTT with tightening with the impact driver so I am waiting for stainless clamp in the post but one side fitteded nicely. The rings I made tightened down fine and still gave the adjustment in angle because of the profile I had achieved by grinding down the sides.
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997.1 C4S CAB

The Finn's 997 4S progress thread take two
 



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Scholester
Suzuka


Joined: 16 Jan 2012
Posts: 1039
Location: South West


PostPosted: Wed Oct 10, 2018 8:49 pm    Post subject: Reply with quote

How long are you going to keep the lid on your other delivery!?
food food food food food food food food food food food food food food
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997.1 Turbo Coupe, manual, black/black. 29k miles under its belt.
 
  
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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Wed Oct 10, 2018 8:53 pm    Post subject: Reply with quote

Haha not too long it's booked in on Saturday for some new rubber so the big reveal after thst just as long as I get the springs swapped on Saturday morning. No pressure
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997.1 C4S CAB

The Finn's 997 4S progress thread take two
 
  
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John997
Silverstone


Joined: 23 Apr 2017
Posts: 114



PostPosted: Thu Oct 11, 2018 10:52 am    Post subject: Reply with quote

Nice bit of DIY mate, all you now need is an order and it will keep you busy for the rest of the year ....

Is that a plaster I can see on your finger - OUCH

Good job Mike Thumb Thumb
 
  
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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Thu Oct 11, 2018 6:21 pm    Post subject: Reply with quote

John997 wrote:
Nice bit of DIY mate, all you now need is an order and it will keep you busy for the rest of the year ....

Is that a plaster I can see on your finger - OUCH

Good job Mike Thumb Thumb


Thanks mate I won't be making any more these were a one off especially with my soft hands that cut too easily
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997.1 C4S CAB

The Finn's 997 4S progress thread take two
 
  
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Phil 997
Brands Hatch
Brands Hatch


Joined: 05 Dec 2015
Posts: 14429
Location: Bournemouth,Dorset

2009 Porsche 997 Carrera 4S

PostPosted: Thu Oct 11, 2018 7:35 pm    Post subject: Reply with quote

Thefinn wrote:
John997 wrote:
Nice bit of DIY mate, all you now need is an order and it will keep you busy for the rest of the year ....

Is that a plaster I can see on your finger - OUCH

Good job Mike Thumb Thumb


Thanks mate I won't be making any more these were a one off especially with my soft hands that cut too easily



Mike I am very impressed that you just got on with making them , so a bit untidy but its in the exhast so who cares as long as it does the job and stops the car looking like a beetle with no tips Grin Grin Saturday you say ok in that case I am Stay Stay Stay Pop Corn Pop Corn Pop Corn Pop Corn Pop Corn Boogie
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911 Owners,Some Invest In The Future,
Others Enjoy The Moment Today.
 
  
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DucatiRob
Barcelona


Joined: 22 Jul 2015
Posts: 1369
Location: Milton Keynes

2006 Porsche 997 Carrera 2S

PostPosted: Thu Oct 11, 2018 8:05 pm    Post subject: Reply with quote

Good job Thumb Just shows what you can do with a little perseverance and a few tools!

These olives/rings are notoriously hard to get hold of! Just need to find a machine shop who can knock out 50/100 off on an auto lathe and and flog them on the forum!
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Present
Carrera C2S Manual
Mercedes CLK DD
Ducati 996
 
  
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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Thu Oct 11, 2018 8:06 pm    Post subject: Reply with quote

Thanks Phil. They were looking pretty good until I couldn't find the dremel parts and just went at them with the chop saw for the ridges but like you said I just thought well it's how they work rather than how they look in this instance. One thing I will add is that I managed to make the elliptical profile as the old ones which give the adjustment where as the ones James made might have looked a bit tidier but they the angels were straight rather than round so I wasn't sure they would work the same, i could be wrong and they might still work fine but I just got too impatient to find out.

With regards to then other mods I am going to have to get them done for definite now a few of you are waiting and I have committed to it, but I have to say mate I went quite bold with the colour but I think you are going to like the results Thumb
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997.1 C4S CAB

The Finn's 997 4S progress thread take two
 
  
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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Thu Oct 11, 2018 8:15 pm    Post subject: Reply with quote

DucatiRob wrote:
Good job Thumb Just shows what you can do with a little perseverance and a few tools!

These olives/rings are notoriously hard to get hold of! Just need to find a machine shop who can knock out 50/100 off on an auto lathe and and flog them on the forum!


Thanks Rob I thought it was worth shot once I found out the dimensions were basically a standard pipe size. I know they are a bit free hand probably more than i would like but as Phil said you don't see them so as long as they work. I know I had a chop saw which not everyone does but I could have also made them with a grinder just being careful.

If there is someone who can make them on a lathe they could just start of with the same size pipe and do a nice tidy job.
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997.1 C4S CAB

The Finn's 997 4S progress thread take two
 
  
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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Thu Oct 25, 2018 8:13 pm    Post subject: Reply with quote

So after a ridiculously busy time for me at work and home life the progress thread is a bit behind a few jobs i have done on the car as i just haven't had the time to update it.

Its been about 6 weeks now since i started lowering the car with the Techart springs i bought at the beginning of the year. The first shot is before i got going on this job with the standard stance which for me is just too high
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The Finn's 997 4S progress thread take two
 



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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Thu Oct 25, 2018 8:19 pm    Post subject: Reply with quote

The actual spring changed over a couple of weekends as i am not the fastest but also like to do other jobs while i am in there. I started with the front end being the hardest to do and also needing the most work, first up was to mark the location of the bolts so that once i had finished the spring change they could go back in the same position. After this the car was jacked up and the wheels and brake calipers were taken off for access. Now although this is one of the biggest jobs i have done on the car for some reason i took the least amount of photos of the whole process. If you are doing this yourself there are plenty of guides to follow as mine wont be the best
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997.1 C4S CAB

The Finn's 997 4S progress thread take two
 



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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Thu Oct 25, 2018 8:23 pm    Post subject: Reply with quote

Once the shocks were out of the car and taken apart i decided to give them a bit of a refurb as they were showing signs of rust, so they were rubbed back with a wire wheel on a grinder. I also did the same with the top mounts as the bushes were fine but the plates a little rusty. Once taken back to metal they were masked up and given a good spray with some matt black
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997.1 C4S CAB

The Finn's 997 4S progress thread take two
 



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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Thu Oct 25, 2018 8:28 pm    Post subject: Reply with quote

while these were drying i gave everything else a good clean and dust off with a wire brush if required, then the barrings were stripped down cleaned and put back together all nicely greased. Then the shocks went back together and back in the car. Both sides of the front were completed but like i said before for some reason i just didn't take many photos of this job so its not much of a write up
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997.1 C4S CAB

The Finn's 997 4S progress thread take two
 



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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Thu Oct 25, 2018 8:34 pm    Post subject: Reply with quote

now unfortunately i ran out of time so the car was parked back in the garage for a couple of weeks until i had time to complete the back of the car. While the car was in the middle of the spring change i had also dropped my new wheels off with a local guy to have them powder coated which is one reason why i was trying to get this job done as i didn't want to fit the new wheels with the standard ride height. I got them back mid week and had the car booked in for new rubber over the weekend as i just couldn't wait so put the pressure on myself to get the rear springs changed, so i found myself changing the rears on a Friday night after work.


First job on the back for my cab is to put the roof into the service position and remove the carpet
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997.1 C4S CAB

The Finn's 997 4S progress thread take two
 



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Thefinn
Österreich


Joined: 11 Jun 2014
Posts: 938
Location: Essex


PostPosted: Thu Oct 25, 2018 8:36 pm    Post subject: Reply with quote

once the carpet was out of the car the nuts to the top mounts were marked again before removing.
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