The trans issues with the super, took me away from the split for a couple weeks. That's all sorted, so back to the '52. :D

Got the "clips" back from the anodize shop. Did them satin black with chrome fastners. Picked them up before work on Thursday, and assembled them afterwards getting both doors done. Here's the 4am, sleepy, blurry phone pic:

http://i2.photobucket.com/albums/y8/...6.jpg~original

Pete

That came out looking very nice.
Is that 5 bar treadplate you have on the floor? I have been looking for a sorce for some 5 bar. Need to make some interior door panels and other stuff for my wifes Pinzgauer.

Wow, those came out beautifully, a very nice touch

How did you end up choosing FX45 projectors? Are they Bi-Xenon? I'm asking as I will soon have one of the Bi-Xenons of my recently damaged 335 and I'm wondering if there is a size difference that makes the FX45 projector a better choice.

Jason

Hi

Pelican parts sell clear Porsche headlight cover. http://www.pelicanparts.com/cgi-bin/...vers%2C%20pair

I'm not sure how optically clean they would be.

Steve

I don't know if its 5bar. I'll have to look again. Alex had got it.


These FX's have been in the mix since 2002ish. At that time they were the only small bi-xenon out there. Not many to chose from back then.

Matt at: http://store.theretrofitsource.com/index.php has helped me out with some items.

Pretty cool. Thanks for the link.



What are your opinions of the yellow 911 lenses above?

Pete

Got the replacement headlight buckets. I hacked out the top mounting tabs. Used some more of the other bucket to make plates that will be used to sandwich the carbon fender with the mounting tabs. Tab and inside support plate are in the middle of the pic.

http://i2.photobucket.com/albums/y8/...5.jpg~original

Did the carbon treatment to the inside headlight bucket:

http://i2.photobucket.com/albums/y8/...9.jpg~original

Need to install the headlight wire conduit, drains, wire the ballasts/high beam solenoid, and trim up the tabs/plates above for final install.

Here it is mocked up, ignore the reflections:

http://i2.photobucket.com/albums/y8/...7.jpg~original

http://i2.photobucket.com/albums/y8/...9.jpg~original

Pete

Hi

Looking very high tech.

I have a set Hella Xenon & halogen modules that I was going to fit into my 1303, but I think that they are going to be too deep and I would have to cut into the headlight buckets.

On my old bug with 17 inch wheels the tyres used to kiss headlight bucket at times.

How much did you need to cut into the back of the headlight bucket?

So now I'm thinking just using stock 911 H4 headlights with a Xenon conversion.

Steve

My Hella modules, they even have self leveling
http://www.clubvw.org.au/images/xenon.jpg

http://www.clubvw.org.au/images/A3_LIGHTS1.jpg

http://www.clubvw.org.au/images/A3_LIGHTS2.jpg

Hey Steve,

I didn't cut the headlight bucket. It still looks like this:

http://i2.photobucket.com/albums/y8/...5.jpg~original

Those self leveling lights would be pretty cool.

Those look killer... you are a sick man Pete! (mad fab skilz)

Nice Work Buddy...
looks GREAT :D

Chris.

Hi

I hope they do the Xenon dance on startup, like the late BMs, Porsches etc.

I have been measuring and double checking and I think I can fit them in, I will have a better look when I get to that part of the project.

Steve

Didn't do much with the split for the month of July. Too many other things going on. Plan to hit it again in the next couple weeks. I'll update.

Pete

That '52 is looking awesome Pete ... looking forward to seeing the progress pics.

Sandeep

Did alot of modding to my daily driver TDI this summer. Took time away from the split. That's why i haven't updated in awhile.

It's getting cold out, so back into the garage. :D

The uniball plates got powdercoated, haven't installed them yet, but they finished up like this:

http://i2.photobucket.com/albums/y8/...0.jpg~original

Next up, the crotch coolers. Toying with different ideas for quite a while.

In this pic, the crotch cooler hole was filled with a piece of carbon that was glued to a fiber plate of some sort. Not functional. The flaps were not available when the car was painted, but i've always wanted to have functional flaps with the carbon.

http://i2.photobucket.com/albums/y8/...0.jpg~original

Tried to source the cooler flaps to gut/grind the hardware apart and try to fix them to a piece of carbon. Not available. Even the guys repoping the parts in South America didn't have those parts. So a OEM set were sandblasted clean and the thinking continued........

Cut apart a Carbon Joe panel for material. It was too thick so shaved/sanded down the 2 layers of fiberglass behind the carbon fiber. Was left with the one layer of carbon fiber, that was to my surprise, pretty flexible.

http://i2.photobucket.com/albums/y8/...4.jpg~original

http://i2.photobucket.com/albums/y8/...2.jpg~original

http://i2.photobucket.com/albums/y8/...3.jpg~original

Now i needed to find an adhesive to get it to stick to metal really hard so i can sand it. Tried different quickset epoxies, instant adhesives, and some Loctite gel stuff. None worked well. Some had a weird reaction with the resin in the carbon, and others dried all rubbery. Gave JB Weld a try, and it was perfect.

A little oversize, and some extra gunk, to allow shaping:
http://i2.photobucket.com/albums/y8/...7.jpg~original

Sanded:
http://i2.photobucket.com/albums/y8/...5.jpg~original

Time to try it out for real.

It's now drying under the weight of some A2 steel, nice and heavy :lmao:
http://i2.photobucket.com/albums/y8/...5.jpg~original

I'll give it a couple days to get hard, before touching it. We'll see how this turns out. :shocked:

Pete

Looking awesome Pete!

The carbon fiber covers on the cooler flaps is, well, too cool!:lmao:
JB weld is the king of adhesives.

Your uniball suspension parts look marvelous;)

Keep up the great work!

Alex

Keep at it Pete. I want to see it on the street.

Oh! Sweet! I really like the work so far.
Git 'er done ;)

nice WORK buddy...keep it Up :)
they are going to look SWEET MAN

Chris.

Beautiful work Pete!

Below other beautiful eyes... Interestingly, the lens is transparent and has the same format as the original 911.

http://i712.photobucket.com/albums/w...1.jpg~original

http://i712.photobucket.com/albums/w...6.jpg~original

more here:
http://www.singervehicledesign.com/

Glad to see the CF crotch cooler doors are staying :) can't wait to see them finished.

I was joking around with someone the other day about led lights and turn signals and the thought of led semaphores came to mind. The mix of new tech and old tech seemed like it would really fit your build. Got any plans for leds?

Sweet door flaps! I used H4 conversion HIDs in my bug for a while until the voltage drop during low idle warmup blew a ballast... Still trying to find something better, with a decent projector that goes in the buckets easy...

:cool: Ah man, this is not a car, this is pure car porn, wow:D

update:

The carbon crotchcooler flaps have been worked over, test fitted, and are ready for inner paint. Hmmm......black or try and match the body paint?

Headlights are FINALLY ready for install. I've nicknamed them....The Million Dollar Headlights. :lmao: I've spend an unbelievable amount of hours to build/fab them.
-OEM FX45 projectors are now modded with clear lenses. Really nice cutoff and colour!
-Ditched the generic clear Oval lenses, and sourced early Split clear Hella glass. Had a local Crystal grinding shop grind a pair of notches in each lens. Notches are to clear the trim's adjusting screws like the later glass, so it can all be assembled.
-Wiring for ballast/highbeam solenoid/grounds done.
*needs to be installed in the fender.

Plastic fender beading will be replaced with repopped Split fender cloth welting. Then the headlights get mounted.

Hopefully tommorrow or Friday, i can get my hands on a completed part i've been thinking of for awhile. I won't spill the beans just yet........I'll get pics up.......

later,
Pete

I may do a LED panel for the small round tailights. Don't want to get rear-ended.
As for the semaphores's lights and solenoids, they are 6V. Is there a 6V LED equivalent of this bulb? hmmm..........

Pete

I think you could find an led bulb that would work just fine as long as you know the bulb size. It might be a little dim if you start with a 12v bulb, but the other option is to build your own with 1.5w or 3w leds.

Not sure the exact voltage but most LEDs operate at only 5V from memory so they would work fine, you couldn't use the off the shelf conversion ones tho as they normally have a built in resistor to drop the voltage down to the correct level and this would be too low with a 6V supply.

These are the specs on the 6V semaphore bulb. Part# N177261 :

http://www.wolfsburgwest.com/img/wwpn/N177261.jpg

Do you guys know of an LED equivalent?

Pete

http://www.ledtronics.com/products/P...px?WP=C296K234
http://www.ledshoponline.com/automot...toon.htm#31smt
they do make them, i saw them in the showroom at automotive warehouse in Niagara on the lake.

any pic sof the headlights installed? I have som eprojectors around at work from Bimers but they all look too deep...

I'll get a couple pics up tommorrow.

Pete

Got my gloveboxes done. Really happy with how they turned out. No more cardboard.....they are carbon. :eek:

http://i2.photobucket.com/albums/y8/...0.jpg~original

I went to pick them up, and he showed me a Kawasaki gas tank he was overlaying in carbon tucked away in the corner of his garage:

http://i2.photobucket.com/albums/y8/...8.jpg~original

So stupid thoughts started racing in my head.........Do the same to the split gas tank? What do you guys think?

Got the headlights together. Opted for the early Hella glass, and had the 2 notched ground into them to fit my housings. Grinding was done by a local Crystal grinding shop.

http://i2.photobucket.com/albums/y8/...6.jpg~original

The slim ballast\igniter\terminal block stuffed in the back of it.

http://i2.photobucket.com/albums/y8/...7.jpg~original

Fired up:

http://i2.photobucket.com/albums/y8/...8.jpg~original

http://i2.photobucket.com/albums/y8/...2.jpg~original

LOOKS great pete... :D
anyword on the running boards??
keep the pics coming
Chris.

Love those headlights

+1 !! VERY beautifull.

Fantastic Pete. That split is going to be a show stopper. Well done !

Sandeep

ooooh, CF tank is very tempting, can't say i've ever seen that done before. Headlights look fantastic and the beam pattern looks pretty good.

Thanks for the comments.

Installed the gloveboxes. Really happy with how they turned out. I'll post a pic later.

Running boards are in process. I'll get back to you with a number hopefully tommorrow. We spoke about molds, and the durabilty needed as it will need to pop out a few sets while being repeatable. So the mold is coming along, and he's crunching the numbers for the actual CF parts. Going by there tomorrow with my CF crotch cooler flaps to finish(spray and blend black). Will try to get him to nail down a number for cost on the boards so we can get this rolling.

Any other parts needed in CF?

Yup , the CF tank is tempting........ But it might be to much CF going on up front(can't believe i said too much CF :eek:). The issue i have with it, is that all the CF on this car is pure CF. No "ricer" overlays. This tank would be an overlay. But on the other hand, it would look awesome! :D

I'm lacking CF out back. Nothing in the engine bay. Will need to figure out what to do back there.

The headlights have a real nice cutoff line. Swapped the OEM FX45 lenses with clear glass from www.theretrofitsource.com. Sharp cutoff.

Pete

How about a type 4 horizontal cooling shroud in carbon :D

I'll even make the mold ! Let's talk Pete as I really need one to finish of my engine. Can't have the bug on the road with out one :(

Can he do door panels / rear quarter panels ?

Sandeep