58367 The $75 Junkyard Carrera coupe restoration

[JTR70]

Front oil line runners now complete. 2/3's of the way there.


Recieved my allen bolts for the clamps yesterday. These are some really trick metric Titanium units found in the mountain bike industry.


Lower hardline fully mounted. I rewelded that first bracket I had cut free and reposition. All insulator rings in and fully clamped down tight. Could not have been happier with it.


The head on the sample bolt I gave Bill was a bit larger then these bolt heads but it will work out fine.


Now that the bottom tube was fully mounted in position I could start building the upper template.

Upper template complete and set. Spent some time here trimming and adjusting for a correct fit. It was an absolute must for me that both lines contour and run even with each other. It has to work but it also has to look good too.


upper line now fabricated to shape. Matches the bottom very closely.

filed and shaped the clamps round. Much nicer round than angular I think.

[JTR70]

Front lines fully test mounted together for the first time. This was a very fun session.


Final configuration.

Just a test fit; insulators will be centered and trimmed when they go in for good.

Everything tucks in nice and tight and I should have no clearance issues.


Left myself plenty of lead for options on how I was going to transition to soft lines.

Both lines pretty much run consistent throughout. If they had not it meant doing it over again.


Keeping these tubes even and parallel as they made this bend was the trickiest. Close enough! The mount bracket has also been rewelded to a more ocrrect position by this time.

I got very lucky; nothing rubs or touches the frame. The Lines are suspended with good clearance. I'm onto the rear sections. Thanks for looking! Justin

[JTR70]

Rear tube runner template


Rear template in development process here. I want them to contour as close as possible with that graceful bow in the chassis.


I soon realized To get these last sections of tube bent up correctly I had to commit on where I was going to place the holes for access into the engine compartment. After some careful thought I commited and made the last of the invasive modifications required to run these oil lines.

Several reasons why I chose down low on the frame rail versus up higher on the closing panel like the factory did. The most important reason was its easily reversable. Its a flat face and will require a simple patch to weld back closed. Also very easy to dress the welds smooth if and when the day comes. Second I can use a bulk-head mounted through fitting to secure both the end of the hardline on the outside as well as a solid anchor point for the softlines. the upper panel is curved so a bulkhead fitting would have been out leaving this junction point unanchored securely without more mods or brackets. Also the access holes would have been egg-shaped and bent to fit the needs of the hardline coming through at an angle. More mess to correct. Not original but much simpler and cleaner for my purposes.


Also easier to access down low here.

Male bulkhead-mounted through fittings will "manifold" right of the wall here and into the softlines up to the filter and thermo units. I'm also thinking the Hot oil from the motor will hardline straight back and up to the thermo/filter junction on the wall there. Got the idea from seeing it done on later 911 SC motors. its slowly taking final form and coming into better focus.


This bracket had to be relocated to get a fit I was happy with. I thought I was done repositioning brackets; Wrong again.


Rear bracket repositioned and welded in place. First and easiest portion of this template complete. Goal was to have this run contour as close as possible to the chassis for a cleaner look.


Rear template completed with Final sections now in position. This swooping curve makes this area far more work then the previous forward sections. Glad I tackled these last and got some practice first.


Full view. Before I commit to a full piece I now realize I should have the fittings on hand so I can accurately position the ends of the tubing in relation to the frame which is dirctly effected by the index of each bend. jim Nelson was nice enough to give me a name of a supplier. Thank you Jim! I'll need to get them here before a can go further and commit to a full piece. better safe then sorry! Thanks for looking at this! Justin

[roy mawbey]

Those pipe clamps with the special allen bolts look so nice. The hours were well spent here no doubt about it. And the isulator rings finish it off well.

Roy

[JTR70]

Thanks Roy, I am glad you like them! You're an engineer so I highly value your comment! I have more time and money in this system than I care to admit but its a labor of love. Thanks again! Justin

Last of the tube collar clamps now completed.


Had to come up with the least invasive way of securing the ends of these tubes.


My machinist Bill finished up the first clamp a few days ago. Based off of the others but built for its own specific purpose. This one had to be built and mounted first so I could engineer the other one.


Stock rocker brace drilled and upper tube collar now fully mounted in final position.

Outer lower clamp now designed and now being machined out of alloy.

Just what I was shooting for; This single hole will be the only modification needed to secure the end of this section. This is also the last modification I'll have to make the car to run this entire system.

Outer lower clamp now complete and test mounted. Works perfectly!

Single bolt in the radious of this base secures both it and the clamp on the other side. Outer cap screws on directly to this base.


Again I prefer rounded shapes so I spent an afternoon shaping these clamps.

All line mounts now complete. Very happy with this setup; only required a single hole in the brace to mount and its very secure. Hardline fittings are up next. Thanks for looking! Justin

[JTR70]

Took delivery of my initial order of oil line fittings; My thanks again to Jim Nelson for recommending a really nice outfit to order from.


Went with XRP (AN style) fittings. they are really nice and are great quality. They weren't cheap so they better be! Pictured here are my front splash pan bulkhead mount 90's with jamb nuts. Need to order 2 more for the engine compartment but wanted to make sure these are what I needed first. The other standard 90 is for the rear turn at the torsion housing.


These fittings are huge!(-12's) I really lucked out on my current spacing of the hardlines. I have ample room to tighen and losen the collar nuts. So lucky, I completely overlooked how big these were going to be.


Thats a stock Carrera sized oil line fitting on the right. This whole oversized system should have that 911 pump flowing real nice.


My original passage holes were based off of that original carrera fitting. Not big enough; had to go the next size up.


Splash pan 90's now fit and have ample clearance from one another. Luckily!

Same story with the rear. I thank god these oversized joints are going to fit and work in my predetermined oil line mounting locations.


One small glitch. The fittings are standard and the lines are metric. We got as close as we could but these tube sleeves are for 3/4 inch tubing and are a bit too large for my lines for a proper fit. I could have used them but to be correct I'm having my machinist Bill fabricate an exact copy only with a proper sized ID for my 18mm tubing. They will make the perfect bridge once done.


Another small custom job I'm having Bill do are the alloy reinforcment rings at the base of each fitting similar to the originals. making the paper template here. looking forward to getting these parts back so I can really start getting things mounted in there on a more permanent level.

Like the tubing bender before you must have the right tools so additional tools were required to complete the lines. Had to purchase this flaring tool for my fittings. Also went ahead and bought a tube cutter to ensure a square tube end before flaring.


This tool is of course set up for standard sizes but a little tape around the tube creates a secure fit in the clamp. You can see what a beautiful job it did on this test section. Thanks for stopping by! Justin

[JTR70]

Here are those critical oil line parts my machinist finished up taking me one more step closer. I had additional fittings on order. Once they arrived I could begin assembling sections of this system.



My new tubing sleeves. These are my bridge to allow my metric tubing to work with my standard fittings; they came out perfect.


Again the Closest standard sized sleeves where just too big and allowed too much wiggle room at the end of the line.


New pieces where made exactly the same size though wth an 18MM ID to work with my tubing.


Last small job were these alloy collars for the splash pan bulk-head fittings. loosely based on the originals but shaped and machined for my specific fitting needs. Had a spare pair made for the engine compartment bulk-head fittings.


Washers trimmed and mimic the originals. Sent these black fittings back by the way for an exchange for silver ones. Wanted them to look more correct.


Don't know if the originals had backing washers but had these made anyway.They are the perfect diameter and just clear one another. Thanks for looking! Justin

[JTR70]

Finally got most of my oil line fittings and hardware together. I'm shy about three pieces still but I could at least begin building some of the system.


Could not get some of the parts in the colors I wanted. The reds will be up by the cooler so it did not matter. The only ones I care about are the 90's at the rocker panel. I could not get the silver ones so they sent the black ones back to me. I'm taking the coating off and just polishing up the alloy. Between order, reorder and machine time to build custom sleeves, washers and clamps there is quite the investment of time and money sitting here.


oil line and fitting in final position. Now to cut it to the correct length without screwing it up! Scary!!


My referrence tools. Two sections cut to the exact same length; One piece flared to tell me how much length is used to create the flare.


Flared mock-up piece in position. Tube will be marked even with the top of this section to give me the correct desired length when fully finished.


Length marked with tape. Unflared piece now used to measure of the correct distance I need for the tube end before flaring.


Tube end now flared and finished. I almost forgot to put the collar and clamp nut on first; Almost!


It worked! Tube wasn't too short and it all sandwiched together nicely.


Bottom run is up next.


Lower section cut and fitted. These tubes actually run parallel much better than in this picture but they are not fully mounted and adjusted.


With the front pieces cut and flared I began working on the rocker tubing lengths.


Snaked it around the access hole with just enough clearance to get a punch in there to drive out the hinge pin if ever needed.


The back of this section is now cut, flared, and mounted in its final position.


Planning the inner tubing run now. Thanks for reading this! Justin

[JTR70]

I soon realized that I'd have to have to remake that inner rocker tube run. This piece fit fine in relation to the hole for the fitting but with the actual fitting in place with its approach angle it became quickly appearant that my bends were not going to allow for proper fitment or clearance for the jack spur and longitudinal. Always something...


Once the fitting was added into this equation it threw all my bends off. it just was not going to fit right and clear the spur and longitudinal as it left the front fitting.I had a very hard time letting this piece die. I had such an investment in time shaping this thing. (page 32) I went back and fourth trying to figure out how I was going to make it work. I eventually cut it in half (pictured) to put any ideas of using it to rest. This now forced me to make a new section.


This was the simpliest path for the tube to take but it looked terrible. I know most will never see this but I need it to look right for the few who will.


After a few tries got the shape I could be happy with and it fit the approach of the fitting while clearing the longitudinal.


I like the path this new run is taking so much better than the first. So at the very least I'm improving the design a bit.

This is going to be a better design all the way around. Simpler to make and much more symmetrical with its mate.


This is a pretty long run of unsuspended tubing. Though I think it would be alright, I'm going to have Bill (machinist) make me one maybe two more of these clamps. This will connect the two runs so they can support one another over this expance without any further modification needed to the car.


More playing around. Just getting a feel for what shape I'm going to need here to make it fit correctly.

A few missing links but this template is just about done.

[JTR70]

Finished the new test model and am now ready to bend up the replacement runner.


Lots of slight bending and twisting adjustments to get the fit I was looking for.


follows the contour of its mate well enough.

ample clearance from the spur.

Here is the model in final shape and clamped position. Folding up the new piece next.

Replacement rocker runner completed. All hooked up and ready. I'm happy enough with the shape but More thrilled to be done with this redo.


some slight tweaking yet to do but its there.

Much simpiler shape than the first one. It clears the spur by MM's but it'll work just fine.


Many slow trial test fits and repeated small incremental bends to creat this sweeping curve.


New line messaged into final shape. Both ends cut and flared with fittings.


I now have my targets for the rear oil line sections reducing the guess work.

Now I am officially 2/3 of the way there once again. Thanks for reading this! Justin

[JTR70]

Oil Cooler soft line fittings

A snag hit in my softline configuration. My original thought was to use 180 degree fittings off the cooler, into a softline back to the hardlines on the wall.


The loops were of course too big and collided with the fender even before they got close to being in position.


The cooler and ducting are set in stone with zero adjustment. So another configuration was needed. After several days of playing with it and letting my brain mull everything over; a 90 degree then to the 180 now pointed downward was the answer. However this configuration required too many extra fittings to work. I sent them back and bought some 90 degree cooler to softline fittings.


Here are the standard cooler to softline fittings I ordered as replacements. They were actually my only other real option. To buy me enough time and space to make the turns cleanly back toward the frame the lines at the cooler must criss-cross.


Fittings and softlines mocked up for the first time. It will work, thank god! What needs to be done is slowly coming into focus.

Facing some real challenges on the other isde of the cooler at the hardlines.

With the cooler and ducting configuration I just recently came to the realization of the corner I have painted myself into. Now that I am transitioning from hard to soft line up here having room to oppperate a leveraged tool to get at the fittings is an impossibility.


My answer came in the form of these trick quick disconnect fittings from XRP.


Double O-ring alloy bung gets welded to the tube end. 90 degree soft line fitting slips right over and this three-prong clamshell locks it all together.


Approximate location of junction. These were not cheap but they solve the problem.


Heres a more detailed pic to show how crowded and limited access a place it is. Physically impossible to get a wrench down in there!

[JTR70]

This oil system is finally getting to a stage of completion where I can begin mounting parts of it on the car on a permanent basis! After taking delivery of some conical seal rings and finishing up that new rocker tube section there was nothing holding me back from mounting this section in for good.



These were not necessary but were just cheap insurance against leaks. I'm not 100% confident in my tube flares but these certainly helped to put my mind at ease.

I could net get my 90 degree fittings in nickle so I accepted the colors they had available. I began removing the anodize by hand but it was a pain. I then read in last months Hot Rod Magazine about oven cleaner making anodize removal a snap.

It sure did!! After a couple of applications it was gone. I Had already cleaned the visable areas of the front rocker fittings and had just finished the rear rocker fittings here. I sure wished I would have known this trick earlier.

Splash pan bulkhead 90's are fully set and sinched down for good! You can see here how those conical seals fit like a glove.

Rocker tube sections were mounted and connected to these fittings shortly after. My biggest challange was NOT to over tighten these things.


Now that the rocker runners were fully mounted the only thing holding me up on getting the fronts in were the tube fittings for the soft lines. All of that had to be TIG welded first.

After a lot of planning and study I committed on the final configuration and ultimate length of each of the runners. Just had to get my buddy Warren to TIG them on for me.

The tube and mating flange of the fitting were about the same size. I accidently came up with flaring the ends to ensure center alignment and ease of welding.

It worked out alright. Here they are shortly after welding.

Welds did not interfere; everything fit fine.

Now test fitted on the car. I staggered the clamshells to ensure good clearance from one another. Its a very tight fit but nothing rubs or touches. I was also test fitting some hose as well.

[JTR70]

Front lines are now mounted into the car for good!! With the TIG welding complete there was nothing holding me back from getting them in as well.


Conical seals installed, just have to hook these up one last time!

Both runners fully clamped and adjusted for even alignment with one another. They both line up just as nice as they did all those months ago. I was so happy and excited!


At long last these are connected for good! Just hope they don't leak!

Being made of harder T6060 a little mothers polish on a rag woke them right up!


The orange insulator wraps have been trimmed back flush with the clamps.


Just a quick overview shot of this hard fought victory! I was so relieved the day I shot these! Just wrapping up the rear runners now. I had to reconfigure them and will post that next. Thanks for stopping by! Justin

[George]

Justin it's starting to look alot like a completed job, keep at it great looking setup. Happy Holidays. George

[merbesfield]

Wow, I am so glad you talked me out of going with an external cooler. I would have never finished my car. Thanks for the nice detailed pics.