962 recreation with a GT3 Heart... - Page 48 - Porsche General - PistonHeads UK

So we've started with a nice low mileage 997 GT3 motor and complete car wiring harness. Have bought a body with most of the panels, and a collection of other 962 related bits and pieces....

We do have some rough plans that give me a clue to the original Tubs outside dimensions, so using them and a Jig built roll-cage that would normally sit on top of the Aluminium Tub we built a rough mockup to check for clearances seating position head height feet positioning and maximum allowable chassis width etc etc. There where no dim's for the axle center lines on the drawing so knowing the WB of an original 962 was 2770mm I had to get an idea of the position of the chassis relative to the axles before I could start doing a Full Cad mockup of the chassis, suspension and engine/gearbox combo. That now sorted its time to start the chassis... Edited by GTRCLIVE on Thursday 17th July 08:17

Awesome project! Thank you for starting a thread on this, I will follow with interest

^^^^ Ditto. This will be a great thread.

Looking forward to progress and updates, Clive! Would have liked to have got up to the Frozen North and seen you before I left the US but there's just too much to do and only 1 week to do it now!

Very interesting project!

Front Bulkhead now set. Carbon Crush structure from a used Original 962...

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Following with interest

Thanks for sharing this, looking forward to following the thread as your car build progresses

Great stuff!

Spent about 20 hours so far from mocking up body to quick cad drawing, and the chassis you see there.... What molds did you buy ? did you pull your body from the molds ??

no body yet. MK 1 moulds, they were on ebay. I will be watching the 962 build closely. they had the Rothmans car at the Philip Island historic classic the other year. Rob Sherrard who also owns the Sauber C9 (not sure which one) also had his 962 out as well. Great to watch them barrel into turn 1 and onto the southern loop. I think I have some photos that I could email you if you wanted. What are you going to do for wheels and tyres, they are massive lumps if I remember correctly, that was the thing that surprised me when standing in the pit garage looking at them, guessing from memory that they were 18” diameter, 12+” wide with a huge side wall, like a 60 profile or something. Will have to go back and look at the photos to see what they were running. It was around 2010 http://www.uniquecarsmag.com.au/news-and-reviews/a... Ryan

More chassis progress. Keeping the box frame so when skinned in ally sheets will look more like a tub. Have used heavy wall for the rear bulkhead as the engine and rear frame will Be supported from it.

Awesome project, looking forward to this...

ezakimak said: no body yet. MK 1 moulds, they were on ebay. I will be watching the 962 build closely. they had the Rothmans car at the Philip Island historic classic the other year. Rob Sherrard who also owns the Sauber C9 (not sure which one) also had his 962 out as well. Great to watch them barrel into turn 1 and onto the southern loop. I think I have some photos that I could email you if you wanted. What are you going to do for wheels and tyres, they are massive lumps if I remember correctly, that was the thing that surprised me when standing in the pit garage looking at them, guessing from memory that they were 18” diameter, 12+” wide with a huge side wall, like a 60 profile or something. Will have to go back and look at the photos to see what they were running. It was around 2010 http://www.uniquecarsmag.com.au/news-and-reviews/a... Ryan Yes the rear tires are a headache as there up there in the 28-30" Dia. Enzo rears get us to 28.5", that's probably going to have to do. The other issue being the cars ground clearance, normally runs at a ride of 55-60mm way to low for any road car. So its going to be lifted for street use to say 75-85mm at a minimum. That means the rear arches will have to be reprofiled, as to how much well we will see when I get the body fitment plates in the right place.... Lots to do but its only F/G and steel both are malleable :-)

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dam, that has come together quick is it a steel or alloy box section that you have the ROPS sitting on? hope you didn't need to much force on the ratchet strap to get it to sit right.

GTRCLIVE said: Yes the rear tires are a headache as there up there in the 28-30" Dia. Enzo rears get us to 28.5", that's probably going to have to do. The other issue being the cars ground clearance, normally runs at a ride of 55-60mm way to low for any road car. So its going to be lifted for street use to say 75-85mm at a minimum. That means the rear arches will have to be reprofiled, as to how much well we will see when I get the body fitment plates in the right place.... Lots to do but its only F/G and steel both are malleable :-) Isn't there a lift option on 997s that could be repurposed?

i presume you have seen this http://vimeo.com/50473835

Book marked - going to enjoy this one.

Lift kit is on the cards, probably one of Frans 4 shock units.. Going to make sure we have 2" of droop on all corners so we can lift it to around 5" all round when needed. Part of the same film crew.... https://www.youtube.com/watch?v=XrhlBWEZ8As Must be my Japanese brother, same mad idea..

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lots of diagonal bracing tomorrow....

50mm x 50mm x 1.6mm steel?

Great thread, looking fwd to seeing you progress. The 962 is an all time favourite of mine.

38.1 x 38.1 x 1.6mm is the majority, 3mm wall thickness at rear bulkhead. 38.1mm Dia Seemless x 3mm front shock towers and diagonal that the towers connect to help move the load out to the dash and front bulkhead, and 25.4 x 1.6mm bracing. Cage was made from 45mm x 3mm....

The vertical will carry the front shock top mount.

Lots more bracing tomorrow....

Thanks Clive, Your doing nice work as per usual. cant believe how quick you are making progress on this thing. If thats 20hrs its amaizing. Ryan Edited by ezakimak on Friday 25th July 08:22

GTRCLIVE said: We do have some rough plans that give me a clue to the original Tubs outside dimensions, so using them and a Jig built roll-cage that would normally sit on top of the Aluminium Tub we built a rough mockup to check for clearances seating position head height feet positioning and maximum allowable chassis width etc etc. There where no dim's for the axle center lines on the drawing so knowing the WB of an original 962 was 2770mm I had to get an idea of the position of the chassis relative to the axles before I could start doing a Full Cad mockup of the chassis, suspension and engine/gearbox combo. That now sorted its time to start the chassis... Edited by GTRCLIVE on Thursday 17th July 08:17 I have just come in from the shed Clive, and been doing a similar task, only for a GT40. I have bits relating to the body and an out of square chassis jig that some one has had a go at. So its been a case of trying to figure out where the bulkheads need to go by measuring from wheel arch to edge of the rear clip then adding a bit 3-5mm for panel gap then the b pillar and so forth. Nothing seems to want to sit square and nothing on the chassis will be able to be a right angles as the engine pokes its way into the fire wall. Your making great progress, i think i have had the stuff sitting there for 2 weeks now and i am no where near getting a chassis tacked up. still reverse engineering. how long have you had that? will be interesting if i can keep up Edited by ezakimak on Friday 25th July 08:26

Total so far about 50 hours now.

http://www.youtube.com/watch?v=nDejfnnMt5U&lis... Walk round of the chassis so far..

Mocking up the engine install, the original car had the motor at a down angle to the front of the car. That's as far as I can tell was mainly due to the gearbox and possibly to help with the diffuser. We can have the engine level to the floor as the gearbox is different, and that will mean horizontal drive shaft angle.... Needed to workout how far apart to put the bulkhead to adapter plate bars, center to center will be 880mm so that plates going to be a little pricy... The third bar that comes from the top of the cage is fine on the right side but it hits the Oil tank on the left. So alternatives to a std tank might be sourced, or we may just have to modify the original and reposition the hose fitting that's also in the way. I've marked the area that needs to be cut out to miss the brace...

Design of the Front motor Mount plate is done. Did a quick MDF template on the Mill to confirm the Hole positions before doing the full design... Now I can confirm the last 2 Tubes that I need to put in the bulkhead as they have to line up to the top outer holes on the plate.

Clive, the speed you're knocking this out at is unbelievable! Very impressive indeed! Can't wait to see the finished article! I still haven't built my 1/12th Tamiya 962 that I bought about 9+ months ago!

GTRCLIVE said: Design of the Front motor Mount plate is done. Did a quick MDF template on the Mill to confirm the Hole positions before doing the full design... Now I can confirm the last 2 Tubes that I need to put in the bulkhead as they have to line up to the top outer holes on the plate. Totally amazing work...

Cheers bud

http://racecarsdirect.com/listing/55089/porsche_96... And for those that want to buy a original 595,000 quid

I thought they were more than that - almost seems good value being about 964RS money

Dom 6 figures not 5.....

GTRCLIVE said: Dom 6 figures not 5..... Tell that to 64RS owners Frankly, at the speed you were moving, I am surprised you haven't finished yet!

2 of the best threads and cars on PH are yours Clive!

Conian said: 2 of the best threads and cars on PH are yours Clive! Your way to Kind bud.... But I can only keep one :-( Then again having all the parts funded by my friend is nice no delays :-) Edited by GTRCLIVE on Wednesday 6th August 20:23

First part of the gearbox extension now here fits fine. Will have to make some Billet blanks to cover the diff cover and drive shaft holes, and give it a good media blasting. Then there's the 3" thick plate that will go behind and adapt it to the Elite Box.

Hi, AWESOME ! How come you've gone for an Elite box?.. Is the GT3 box not an option?

Needed to space the gearbox back 15" to put the engine in the right place, and having a new gearbox built means I can spec the input shaft long enough to still fit up to the Engine. Plus full Sequential

So, has this build be commissioned by someone else, effectively, Clive? I wish there was someone over here doing a 962 like that!

Over here ?? Canada is only a small drive away from Texas... I'm driving to Vegas later this year..

GTRCLIVE said: Over here ?? Canada is only a small drive away from Texas... I'm driving to Vegas later this year.. Back in the UK now, matey! We're even having the same weather!

I love your projects Clive. The amount of progress you make in such a short time is staggering. The only problem is the wait between the bursts of activity. I do have a question for you though: A 911 is rear engined, but a 962 is mid engine. How do you get the power train to effectively work in reverse?

My Day job is 12 hour shifts 4 on 4 off, so yes I only get say 3 days a week at it at best. The engine I still have to ask about yet, there maybe some work internally needed for the oil pickup but that's probably all the mods it needs. Anyway adjustable Corsa 'C' EPAS column arrived today, as did the AC / Heater unit AC unit fits fine but has to be pushed right over to the passenger side to keep it away from the drivers feet. Oh yes and there's a original Heated windscreen, dont ask how much that was....ouch

^^^ ^^^

What an awesome thread, genius

GTRCLIVE said: Anyway adjustable Corsa 'C' EPAS column arrived today Fascinated by what you're doing with this - looks great! What ECU are you using for the EPAS? I built an LS3 powered TVR Sagaris race car using a Tuscan Challenge rolling chassis as the base, with a Holinger sequential, full MOTEC etc. I fitted a Corsa column with the GM EPAS ecu and one of the those rally things to give it a speed input. The thing was a nightmare - the steering was far too light even at the heaviest setting. It gave assistance when unwinding lock so you would go over-centre. The GM ECU would also overheat mid corner (unsurprising as the load on the steering with 10" slicks was somewhat more than a Corsa) and it would briefly shut down - meaning no assistance - before switching back on. All in all it was really dangerous on track and I did a season with it switched off. I then fitted a DC Electronics motorsport EPAS ecu. It was expensive, but what a difference! After some fine tuning I got the steering weight spot on, and by playing with the adjustable steering maps I had it set up to give more assistance in slower speed corners - hairpins - and less in faster corners. Elite wouldn't be my choice of box for this - but the alternatives are likely massively more expensive... How much torque are you putting through it?

Awesome thread! Only used elite to rebuild a sequential ricardo box and a gemini transmissions box, both for my old gt2 racer, then again when I sold the boxes. Great to deal with. Thats what mark there asked me (how much torque you are going to use) under 500lb I think he said his boxes are bomb proof, you should be fine with the gt3 engine. In some ways i wished i hadnt used a hollinger upside down like I have in my cayman, a lot of work and you are limited by how far forward the engine is v where the gearbox output shafts are

Wow, just wow! Respect!

Yes keeping Stock GT3 motor for now with a different exhaust (Side exit of course) and maybe a tune shouldn't be any more than 350 lbs of torque. Even we we play with the motor later keeping it under the say 450 lbs should be easy. Plus we live in Calgary so most of its use will be a 3300ft above see level that's a good 5-10% loss of power up here in the mountains. Yes Spoke to DC for my project so going to order 2 Ecu's at the same time, glad to here another guy using them with good feedback... Did you keep the stock torque sensor on the column or fit DC's sensor ?? On the gearbox front I spoke to Elite today and I can have 5th and 6th cut helical which should make it a little more normal at cruising speeds, got the idea after remembering the Old Jack Knight Mini Boxes that only had top gear helical and straight on the others, thought it would be cool...

Well not so much done in the real world today but the Cad model has moved on loads... The uprights I have designed and used on my car have the rack in different position, so back to the drawing board for them. Tried to keep them simple so radial mount calipers bolt direct no brackets, and a simple sandwich plate design for the upper ball joint and steering joint. Similar to this original but modified 962 Here's my version... Edited by GTRCLIVE on Saturday 9th August 01:28

As you can see the only flat part of the underneath of the chassis is under the drivers seat, the rest is contoured I'm hoping to keep as close as possible to the original on this as the best part of a 962 was is ground affects, and that lovely bloody great big Diffuser.... We don't have any diffuser panels, so I will have to scratch build one similar to this... Edited by GTRCLIVE on Monday 5th January 22:44

hunter 66 said: In the pits later ..... had a lot at the Turbo .... holy that is a big un .... I bet that had a good bit of lag, but a real kick in the ass when the boost comes in!!!!

Oh yes .... raced old school Porsche turbos .. but that must be amazing an on off switch of huge power surge ......

hunter 66 said: Bob passed me on the Banking in Daytona .... free practice in this and it looked amazing form where I was sat ........ That sounds a real story would you mind sharing more?

Wow, thanks for sharing. Sounds a great experience. NB your picture of your GT3 covered in snow is one of my favs. Cheers Ed

Yes there where 2 stages of over rev, and a car with PDK I also thought how does that even happen... but the knocking made it a simple decision... Great Story must have felt like a F1 Car going past you...oh no It probably sounded better than a Present day F1 Car

The Banking for the first time at Daytona is a surreal experience ....

I've stood at the bottom where the Bumps used to be just above the narrow tunnel. It's nuts and I'd love to drive it in anger...

Hunter you have your mucking names fuddled ,bob has sadly been dead for quite a few years,dont you mean the irish contingents ,they were deff driving,but i could not see bob through the window. Ah hang on a minute it was elvis i remember!;) I took the editor of a porsche mag out in a 962,it was twin turbo so a little better to drive,brutal acceleration,amazeing proper aero,no traction control,pdk rear wheel steer etc. I do know where there may well still be a full set of body moulds sat in a container in New Zealand if any help.

Haha so I have .............I was in Heaven ..

Haha yes one o the best events to do ... and spectate for fun . Classic Daytona ( on in 2 weeks ), was midway up the second Banking in Free practice on the Wednesday in my 2001 GT3 RS and had a look to my right at the car moving past me which was this driven by Jochen Mass .... who gave a little wave ( we had shared a breakfast at the hotel in the morning ) ...... but the event is one of so many moments .... plus the weather is still great at this time of year ....here on the banking Edited by hunter 66 on Saturday 27th October 20:29 Edited by hunter 66 on Monday 29th October 09:06

Hi Clive, This is such a crazy thread. I'm not sure what will be required for a guy to start in earnest. But I would think if someone went all in on that crazy looking X Trac Daytona Prototype Sequential 6 speed Transaxle, it sure would be a good start. And getting all those rare parts like tail lights etc would be neat to see too. [url] Clive, be sure to let us know how things work out with your perspective new client. I cant wait to watch the next build. I sure hope he takes the more authentic route with the build. It would be great to see a road going race car replica. I'm really looking forward to seeing the build. Might give me some inspiration. You do beautiful work. Thanks for posting. You could get a guy in to a lot of financial trouble with a thread like this. Have you heard anything more from your client? Any updates you can provide? Edited by Vectorw8015 on Tuesday 2nd April 17:30 Edited by Vectorw8015 on Tuesday 2nd April 17:37

Now Now Mr Vector...... Looking at that Xtrac does make me think I should have not told you about it and Bought it myself... and Yes boys and girls this is box for the next 962 I'm starting to build very soon... If anyone's interested where's the best pace to put a new thread ?? new title "962 with 996Turbo / Xtrac heart"

New thread on PH and soon. Need to see more of the workshop too. Steve

Hope the right thread is that your new workshop vid on youtube! If so I have workshop envy, v nice!

Baron Greenback said: Hope the right thread is that your new workshop vid on youtube! If so I have workshop envy, v nice! Link? EDIT: Edited by shalmaneser on Wednesday 13th May 11:53

That the one!

Baron Greenback said: Hope the right thread is that your new workshop vid on youtube! If so I have workshop envy, v nice! Thanks shop and house reno have killed me, but there nearing the end now... Kurt's car will be the next 962, but I will be mocking up my ally Tub car at the same time. So 3 full builds side by side should be fun....

Epoxy flooring worth every penny .. no give it a week to dry and get the 962 out

No, still epoxy ceiling

Wow the floors so shinny the PH photo app keeps flipping the picture upside down ??

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well it must be something to do with the Mobile upload as its done it again..... not annoying at all gerr

Good to see you posting again. Didn’t realise you’d moved to aus though.

Gaday mate

GTRCLIVE said: well it must be something to do with the Mobile upload as its done it again..... not annoying at all gerr IIRC it does this if you use a fruity device. When you take a photo it records the orientation of the actual device into the photo rather than which way up it should be. So if you take a photo with the phone upside down the phone is clever enough to flip it but the uploader just goes "Ok, photo was taken this way up with respect to the phone so it goes this way". ...and sticks it upside down. Anyway, nice ceiling!

GTRCLIVE said: well it must be something to do with the Mobile upload as its done it again..... not annoying at all gerr If in doubt take a screenshot of the photo on your phone and upload that, always works.

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Well at least it’s the right way up

Nice update vid and love the space on your garage.

Baron Greenback said: Nice update vid and love the space on your garage. (Vid in question) Comments are disabled on the vid but also want to say great update! Edited by Brother D on Sunday 6th December 22:32

Suddenly had a flashback to this thread... you will all probably want to murder me for bumping it but... Any news Clive?

Last video was a couple of weeks ago. I really don’t understand how this gets fewer views than two blokes piddling around with a mini.

Wow there are vlogs! subscribed, can't wait to catch up. This is such a cool project.

Oh FFS - I never actually thought to go to the YouTube channel and subscribe! Doh!

Makes a change to have someone on YouTube who definitely knows what they’re talking about.

Well the 962 that’s left me in for its new owner in 2017 is now on eBay if anyone interested. It’s been an odd journey with that car to be honest but one I would do again in a heart beat. But on brighter news a friend that was so impressed with the chassis and engineering that went into it, he decided to replicate what we did. I’ve helped him when I could, his car is In Europe and thats where he sourced the body . He has since 2017 built his complet car, and it’s now finish painted and running a 996 Turbo motor.

It’s an absolute credit to him and so happy that it’s going to used on track and road very sooo. …

This thread needed a good news ending, and I’m glad Lars helped me with that. I do have another friend that’s toying with the idea of me building him another 962, so you never know there maybe another one left in me yet. Anyway thanks so much for following me on this journey. More cars planned once I’ve finished my monster , then I’ll be building them mainly for me and my Daughter.. Got an Esprit next on the list with a lot of my input on the chassis and of course and a 600 HP RS4 Audi engine and trans … see you soon Clive Edited by GTRCLIVE on Saturday 17th May 02:36

Great update and pics, Clive! I'm off to eBay!! My ebay skills have failed me... do you have a link? Edited by dom9 on Saturday 17th May 10:16

https://www.ebay.com/itm/187219344817?mkcid=1&...

Just a simple note I had nothing to do with the wiring loom that’s on the car now. We were going to run an Original Porsche loom with Dash. But it seems that’s was to complex for who ever had the car in there shop. I belive it still has the body even though it’s not in the pictures . Just not presented very well with all the dust on it . Makes me Cry a little inside seeing it like that TBH.

Thanks for the link! Wants another $60k to finish it but then... seems a lot of car for the money!

This was such a cool thread great to see a good ending.