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Han Solo
Joined: 11 Jul 2015
Posts: 249
Location: Lebanon TN
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 Posted: Wed Nov 16, 2016 2:53 am Post subject: Rear fender flares |
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Started in on the rear flares last night. Hung the flare with painters tape for exact positioning. Then outlined with a sharpie. I'm going to cut the wheel well 1" back from the OEM opening. There's an inside layer that will probably have to be re-joined to exterior skin with welds. I think I'm going to use a cut-off wheel instead of body saw. Note that the passenger side has some poorly repaired dents that will be mostly covered by the flare. There's one area by the passenger door where I'll probably encounter body filler.
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-----HAIRY ANT NEST RACING-----
Collecting, racing and restoring Porsches for fun and negative cash flow.
-----Epic 914 race car build----- http://forums.pelicanparts.com/porsche-914-914-6-technical-forum/767721-yet-another-rescue-porsche.html |
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Rasta Monsta
Joined: 12 Jul 2006
Posts: 11733
Location: PacNW
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| Posted: Wed Nov 16, 2016 3:39 am Post subject: |
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Cool!
Fyi, there is a sub forum here dedicated to body projects.
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Toofah King Bad
- WeiBe (1987 924S 2.5t) - 931 S3
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Han Solo
Joined: 11 Jul 2015
Posts: 249
Location: Lebanon TN
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joecitizennn
Joined: 12 Sep 2005
Posts: 2096
Location: no mans land
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| Posted: Wed Nov 16, 2016 4:43 am Post subject: |
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I would cut a little higher than 1" at the top unless you are planning on rolling the remaining steel up and out of the way. You will need more room for suspension travel.
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87 924s
88 924SE gone
447 hp cgt clone
87 924S gone
84 944 sold
83 944 sold
89 turbo S LSD, ABS etc
86 951 white rocket
85 944 sport everything.
84 944 sold.
87 944 sold |
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Han Solo
Joined: 11 Jul 2015
Posts: 249
Location: Lebanon TN
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| Posted: Wed Nov 16, 2016 5:04 am Post subject: |
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| joecitizennn wrote: | | I would cut a little higher than 1" at the top unless you are planning on rolling the remaining steel up and out of the way. You will need more room for suspension travel. |
Yeah, I'm looking at that. I'll be running 275 x 35 x 15 Hoosiers which are considerably smaller O.D. than OEM so clearance should be fine. I've lowered the rear control arms and don't plan on getting any lower unless corner balance is not good. That would entail re-indexing the torsion bars and we all know how much fun that can be 
Also, I just read through Hugo Jacobs DYI and I'm not sure I'll do that method. He basically created an inner liner using the flared material. I can see a need for that on a street or track car but autocross is different. Much shorter distances and duration. I like this method though...
https://www.youtube.com/watch?v=yGrGvuvxq-o
Except for the riv-nuts. I'll fix the flares with pop rivets or sheet metal screws and then fiberglass the flare to the car (maybe with some assist from adhesive). Drill out the rivets or extract the screws, body fill and finish.
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-----HAIRY ANT NEST RACING-----
Collecting, racing and restoring Porsches for fun and negative cash flow.
-----Epic 914 race car build----- http://forums.pelicanparts.com/porsche-914-914-6-technical-forum/767721-yet-another-rescue-porsche.html |
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morghen
Joined: 21 Jan 2005
Posts: 9095
Location: Romania
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| Posted: Wed Nov 16, 2016 7:13 am Post subject: |
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Cut more, just to be sure.
I did not weld the panels, i treated for rust protection and then used polyurethane glue to fill the gap. No rust and no leaks in...must be over 10 years now.
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joecitizennn
Joined: 12 Sep 2005
Posts: 2096
Location: no mans land
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| Posted: Wed Nov 16, 2016 7:20 am Post subject: |
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The cutting of the wheel arch is related to wheel travel. You do not need to remove metal in front of or behind the tire, just above it where it will travel. 1" is not enough. 3" and a little forward for the swing of trailing arm.
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87 924s
88 924SE gone
447 hp cgt clone
87 924S gone
84 944 sold
83 944 sold
89 turbo S LSD, ABS etc
86 951 white rocket
85 944 sport everything.
84 944 sold.
87 944 sold |
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Carrera RSR
Joined: 08 Jan 2010
Posts: 2312
Location: Somerset, UK
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| Posted: Wed Nov 16, 2016 8:36 am Post subject: |
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http://www.iribbit.net/i/_files/924cgt_rear_flares_by_hugo_jacobs.pdf
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1980 931 - forged pistons, Piper cam, K27/26 3257 6.10 hybrid turbo, 951 FMIC, custom intake, Mittelmotor dizzy & cam pulley, H&S exhaust, GAZ Gold, Fuch'ed, Quaife
Now www.924board.org/viewtopic.php?t=34690
Then www.924board.org/viewtopic.php?t=31252 |
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Han Solo
Joined: 11 Jul 2015
Posts: 249
Location: Lebanon TN
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| Posted: Thu Nov 17, 2016 12:16 am Post subject: |
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| joecitizennn wrote: | The cutting of the wheel arch is related to wheel travel. You do not need to remove metal in front of or behind the tire, just above it where it will travel. 1" is not enough. 3" and a little forward for the swing of trailing arm.
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Agreed. I compressed the rear suspension, measured to the 1" cut on the sides 16.5" and then made an arch over the top to match. Should be plenty of room for travel. Note that your picture has a 225 x 50 x 16 tires and I'll be running 275 x 35 x 15. That's a 26" tall compared to 22.5". I think I'll be fine unless I move into a 16" wheel which is unlikely.
_________________
-----HAIRY ANT NEST RACING-----
Collecting, racing and restoring Porsches for fun and negative cash flow.
-----Epic 914 race car build----- http://forums.pelicanparts.com/porsche-914-914-6-technical-forum/767721-yet-another-rescue-porsche.html |
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19marty73
Joined: 28 Aug 2012
Posts: 25
Location: Wirral. UK
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| Posted: Thu Nov 24, 2016 2:33 am Post subject: |
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| Brave cuts my friend. I think this rear arch modification stops a lot of people carrying out a 924 GT conversion. I have been pondering this exact modification since 2001! looking forward to see the progress. |
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Han Solo
Joined: 11 Jul 2015
Posts: 249
Location: Lebanon TN
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