great work so far, I like your project alot. I just put your photobucket account on follow :D Please keep the gearbox install pictures coming, I'm very interested, because I'm right behind you, having aquired a 915 gearbox :D

Looking good! :)

Thanks for your kind words everyone :)

hoping to upload some more pics tomorrow!

made some progress but its mostly been saturday work....which haven't been that productive as we've had a couple of bbqs at work and ive just got a mk2 golf that im tryin on the road as a daily!

but here are a few pics

managed to get a porsche coupler and rod which ive spliced with the beetle shift rod - will be able to make fine adjustments for shifting now! i also installed new bushes

http://i591.photobucket.com/albums/s...1.jpg~original

fitted hi pacs - quality products!!

http://i591.photobucket.com/albums/s...5.jpg~original

http://i591.photobucket.com/albums/s...0.jpg~original

http://i591.photobucket.com/albums/s...4.jpg~original

http://i591.photobucket.com/albums/s...6.jpg~original

http://i591.photobucket.com/albums/s...5.jpg~original

welded up the holes in the moon vent and ground them down with a dremmel - it was a right bitch of a job - also welded up all the holes in the firewall and ground off the tages for the old tar firewall.

http://i591.photobucket.com/albums/s...2.jpg~original

http://i591.photobucket.com/albums/s...3.jpg~original

also fitted the rear valance, wings and decklid and spent a couple of hours fettling making sure it all aligned properly - need to get better pics of the valance though to show how ive done it.

http://i591.photobucket.com/albums/s...7.jpg~original

http://i591.photobucket.com/albums/s...7.jpg~original

http://i591.photobucket.com/albums/s...9.jpg~original

http://i591.photobucket.com/albums/s...0.jpg~original

mmm bbq

http://i591.photobucket.com/albums/s...5.jpg~original

Looking good. Keep the pix coming.

That Barby looks good tooo!

Jason

Thanks guys....you can see why i became destracted then :lol:

done a bit more

boxed in the boot floor - tried to replicate the pressings using the bead roller!

http://i591.photobucket.com/albums/s...8.jpg~original

http://i591.photobucket.com/albums/s...9.jpg~original

http://i591.photobucket.com/albums/s...1.jpg~original

http://i591.photobucket.com/albums/s...8.jpg~original

Phatbug03 was kind enough to let me borrow his case and fan to mock up......and im glad to say.....IT FITS :D decklid shuts with no probs!

http://i591.photobucket.com/albums/s...4.jpg~original

http://i591.photobucket.com/albums/s...3.jpg~original

his is a early 911 fan and mine is a 964 fan but i doubt it will make any difference. ive got some better pics with the decklid shut - showing about 30mm of clearence

i also removed the bonnet seat strips off of the front - and cleaned the rust underneath.

http://i591.photobucket.com/albums/s...9.jpg~original

http://i591.photobucket.com/albums/s...0.jpg~original

http://i591.photobucket.com/albums/s...1.jpg~original

and been teaching the misus to weld! shes doing pretty well!

http://i591.photobucket.com/albums/s...5.jpg~original

nice project!, more peeks!

thanks ragtop81 :)

here are some more pics!


ive done a little more, test fitted the doors, front wings and bonnet!

http://i591.photobucket.com/albums/s...0.jpg~original

http://i591.photobucket.com/albums/s...9.jpg~original

it all lines up pretty well although i do have an issue with the bonnet sitting slightly proud in the middle which is a little odd as its a NOS genuine item. im going to fit another bonnet this week to see if its the bonnet of scuttle but im sure i can tweak it a bit to get it to fit.

http://i591.photobucket.com/albums/s...4.jpg~original

welded up the radio hole and the old drain area by the fuel tank

http://i591.photobucket.com/albums/s...3.jpg~original

then i took off all the wings again and unbolted the chassis so i could get the shell on tressels to spot weld on the bottom plates

http://i591.photobucket.com/albums/s...1.jpg~original

http://i591.photobucket.com/albums/s...2.jpg~original

i also finished off the welding on the fornt bulkead, and the 1/4 strengtheners that attach at the back of the front clip

http://i591.photobucket.com/albums/s...7.jpg~original

http://i591.photobucket.com/albums/s...8.jpg~original

I also took a couple more pics of where i boxed in the boot floor for the 915 gearbox - underneath

http://i591.photobucket.com/albums/s...8.jpg~original

http://i591.photobucket.com/albums/s...1.jpg~original

http://i591.photobucket.com/albums/s...2.jpg~original

http://i591.photobucket.com/albums/s...4.jpg~original

a couple of hte chassis almost finished - i just need to change some brackets for the brake lines and re route the throttle cable tube

http://i591.photobucket.com/albums/s...3.jpg~original

http://i591.photobucket.com/albums/s...6.jpg~original

http://i591.photobucket.com/albums/s...9.jpg~original

i also won these 996 rear calipers on ebay for half the price i was willing to pay :D

i was a bit miffed when i received them though as they were suitable for 986 discs instead of 996 discs (4mm thicker) so i pushed the pins back to where they should be which was more effort than i thought it would be.
before

http://i591.photobucket.com/albums/s...8.jpg~original

http://i591.photobucket.com/albums/s...0.jpg~original

after

http://i591.photobucket.com/albums/s...7.jpg~original

ive pished each pin out by about 3mm

theyl be refurbed and mated to my 944 T a arms and 996 rear discs with an ally adapter

http://i591.photobucket.com/albums/s...0.jpg~original

and now the bugs back on its pan again

http://i591.photobucket.com/albums/s...1.jpg~original

ive got about half a day of tieing up lose odds and ends then its ready for prep and paint! whoop!!! :D

Great job on the calipers! I never thought of pushing the pins outside, good solution. How did you actaully do that as you can't just hammer them from the other side..?

Thanks, i used a large G clamp - and a thin peice of wood to i didnt damage the face of the caliper. i gues i should really drill out the roll pin - and replace it.

i am a bit confused why they were wrong though - the part number is a 996 rear caliper part number - but the pins were 23/24mm apart - so i gues they were used on the back of a normal boxster (20mm disc) not the boxster S. strange one.

Looking great so far! :)

Wow! Awsome car! Great prgress!

Thanks for the comments guys!
well ive not updated this for a while because ive mainly been rubbing for 2 months lol! Ive been prepping the car with my mate craig who's going to paint it for me. so far i rekon we've put in around 200 hours which may sounds like a lot but we;ve gone to pretty good detail inside and out. All the leading and filler work has been done and the car is now im primer (no pics yet), which now just needs wet flatting and the booth is booked for the 13th Nov, 2days before my birthday :D anyways here are a few pics!

http://i591.photobucket.com/albums/s...3.jpg~original

http://i591.photobucket.com/albums/s...1.jpg~original

http://i591.photobucket.com/albums/s...9.jpg~original

http://i591.photobucket.com/albums/s...5.jpg~original

http://i591.photobucket.com/albums/s...5.jpg~original

http://i591.photobucket.com/albums/s...8.jpg~original

http://i591.photobucket.com/albums/s...3.jpg~original

i also finally finished my chassis which is going for blasting and powdercoating next week. i had to set where the shift rod attaches to the gearbox so i could get all gears smoothly and drill the dimple which wasnt easy! that metal is real tough! i also had to change a couple of brackets for the brake lines

http://i591.photobucket.com/albums/s...4.jpg~original

http://i591.photobucket.com/albums/s...5.jpg~original

ive also been buying all the little bits i need to build the car up including all rubber items! these are my favorite things, new genuine bonnet handle, rear catch and hella light rims.

http://i591.photobucket.com/albums/s...3.jpg~original

ive been trying to get new genuine door handles but dont seem to be suceeding. i think il get my old items rechromed but they do have some light pitting.

http://i591.photobucket.com/albums/s...4.jpg~original

http://i591.photobucket.com/albums/s...5.jpg~original

Ordered up my fuel lines and clutch lines

http://i591.photobucket.com/albums/s...7.jpg~original

so yeah its all starting to come together. the last two months have drained my will to live, and my bank account lol - i just hope its worth it!