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The Carrera Project

M mickey356
I figured instead of jumping around in different threads I'd settle in here and just post progress on my Carrera project for those who have an interest.
Not of be redundant I'll spare you all the crap I've already posted on other threads.
I spoke with Pat at CB today. He said he's just waiting for the enigne tins back from the powder coater and the A1 exhaust and he should be done with my new engine by the end of next week! He's shipping my new transmission with it so things here will be getting greasy in about 2-3 weeks!
I made an attempt to put in the rear swaybar today. As things have been, this was no exception, it didn't fit. It's made for a stock set up and since I put the new trailing arms in the brackets wouldn't fit. So I eother have to grind off a small notch on the new arms to fit the bracket or weld the bracket to the new arms. I still have to deal with the shock alignment as well. It's looking like I may just have to suck it up and put my little car on blocks for a few weeks and get this stuff done in one long session.
The rear narrowing has been a bit of a hassle. I don't know what Air Cooled was thinking when they made those arms. Whatever it was it wasn't for a stock application.
Between the shock issue, the rear sway bar, and those tabs that connect the frame to the torsion bar housing, I think I'm going to be learning how to weld in the near future. Fortunately it's all under the car so it doesn't have to look pretty, just be solid.
I was hoping to do all the individual aspects in day or two stretchs but it's just stupid. I threw the car up on the lift because I had an hour of free time to put the sway bar in. When I found out it wouldn't fit I had to reconnect the arms and spring plates, put the wheels back on, ect.... blah, blah, blah, I've done that a few times over the past week or so and it's frustrating to remove everything only to find out you can't do anything about it at the moment. So after I hear fomr Pat as to when exactly my engine will be shipping, I'm going to pick a day and put the car on blocks until the front brakes, the engine & trans are in and the rear end modification has been sorted out.
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M mickey356
I figured instead of jumping around in different threads I'd settle in here and just post progress on my Carrera project for those who have an interest.
Not of be redundant I'll spare you all the crap I've already posted on other threads.
I spoke with Pat at CB today. He said he's just waiting for the enigne tins back from the powder coater and the A1 exhaust and he should be done with my new engine by the end of next week! He's shipping my new transmission with it so things here will be getting greasy in about 2-3 weeks!
I made an attempt to put in the rear swaybar today. As things have been, this was no exception, it didn't fit. It's made for a stock set up and since I put the new trailing arms in the brackets wouldn't fit. So I eother have to grind off a small notch on the new arms to fit the bracket or weld the bracket to the new arms. I still have to deal with the shock alignment as well. It's looking like I may just have to suck it up and put my little car on blocks for a few weeks and get this stuff done in one long session.
The rear narrowing has been a bit of a hassle. I don't know what Air Cooled was thinking when they made those arms. Whatever it was it wasn't for a stock application.
Between the shock issue, the rear sway bar, and those tabs that connect the frame to the torsion bar housing, I think I'm going to be learning how to weld in the near future. Fortunately it's all under the car so it doesn't have to look pretty, just be solid.
I was hoping to do all the individual aspects in day or two stretchs but it's just stupid. I threw the car up on the lift because I had an hour of free time to put the sway bar in. When I found out it wouldn't fit I had to reconnect the arms and spring plates, put the wheels back on, ect.... blah, blah, blah, I've done that a few times over the past week or so and it's frustrating to remove everything only to find out you can't do anything about it at the moment. So after I hear fomr Pat as to when exactly my engine will be shipping, I'm going to pick a day and put the car on blocks until the front brakes, the engine & trans are in and the rear end modification has been sorted out.
Willy PWilly P
Keep the faith! When you complete your car, you will be in the position that I envy. You did most of your car your self. The pride in creating your car yourself really makes these "replicas" more special to me than a 1957 356A Speedster that some guy sends to Willhoit along with a $150,000 check to restore, and then looks down on owners of replicas that they did substantial work creating. You will be real happy with YOUR car!
M mickey356
Thanks for the encouraging words. I know at times it may seem like I'm bitching alot (because I am) but I know it'll all pay off. I'm not one to quit or be completely discouraged by set backs. In hindsight it was my own stupidity that thought this was something that could be done while still enjoying the summer drives. I didn't anticipate the "little things" that pop up. It's better to just put my head down and gut this out until it's done and not worry about driving the car for now. I just hate the idea of giving up my 9pm cruise through the twisties at night. But, if all goes well, I'll still be able to get plenty of drivng in during September and October.

Cory,
As I've said before, I love my wife and children too much to widow and leave them fatherless. The Hoopty and I will just have to continue with our once or twice a year encounters. The nice thing is that maybe I'll have something that you'll get to enjoy driving too.
M mickey356
Carrera Project Update:
Got an email from Pat Downs at CB Performance today. We've run into a few delays with the engine but it should be going out tuesday next week. So I'll be VERY anxious to get started on all the work once it gets closer.
Not only am I switching out the engine and trans but while it's out I'll be doing the chassis reinforcement, relocating the shock mounts on the new trailing arms, and reattaching the body to the frame to make it even. And of course anything else I find under there that needs tending to.
I got the carrera bumper trim on the rear bumper today along with getting my door tops recovered. Tomorrow I'll be doing the front bumper trim and putting the door tops back on so I can start on the new side curtains. One drag with the bumpers is I HAVE to keep the bumper guards on them. I really don't want them there because the originals didn't have bumper guards but with having to park on the street it's a necessity. I figure when I can take them off I'll just clean up and paint a flat head bolt to cover the holes from the guards. I came home late sunday night in my other car and when I drove up the street I saw the rear bumper on my speedster was all torqued. I got out to take a look and someone had slammed into the back of it. They hit so hard they bent the bumper bracket (1/4" x 2" steel). My bumper was pushed all the way up against the body and it scratched the paint pretty good. So needless to say the bumper guards are essential. Otherwise I'd be buying new reflectors, license plate lights, and rear light lenses on a fairly regular basis.
CIP1 is still out of stock on the front disc kit so I can't move forward there.
Hopefully more to come soon.
FM Former Member
WHAT ! ? ! ? ! ? ! ? ! ? ! ? ! ! !


Someone hit your car and ruined the rear end !?!?!?!?!?!?!?!



If you need another fiberglass rear bumper, I have one right here for you! Just lemme know, OK?

Holy CRAP ! ! ! You can't park that on the street. Park on the lawn if you must, but get it off of the street!


YIKES !

M mickey356
Everything is fine with the car. All things considered the car took the shot pretty well. If it weren't for those bumper guards it would've been much worse. I only had to pound the bumper bracket back into shape and then reattach the bumper. Once I get the carrera trim on the front bumper I'll spend some time making sure bith bumpers even and level.
Unfortunately I have to park on the street, the wife gets the garage. Sometimes I have to park as far as two blocks away when I get home at night. It's one of the main reasons I won't spend the money to get the body super straight or spend a ton on a quality paint job. The car is too vulnerable. Some day when I have a safe place to put it at night I'll splurge, but until then I'll do the body work and get Maaco to spray it again next spring.
I'm committed to making this car as good as it can be structurally and mechanically for now. When the time comes I'll dress it up all nice nice.
I may end up replacing the floor this winter and seeing what can be done to reinforce it more on the underside. I'm also considering a rollbar welded in. Not only for the look, but for a little more structural integrity.

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M mickey356
Got a call from Pat today. The engine will ship out tomorrow and it'll be here by the end of this week or the begining of next week. Bitter sweet news because my buddy is closing his shop for vacation next week. I'll have to toss and turn every night for a week knowing that my engine is here but there's nothing I can do about it. CRAP! Oh well, it's all good. Pat says it put out close to 150hp on the dyno!!!! So between that and my new tranny it should do OK for a grocery getter.
So, I'll have to decide whether or not to get it ready this week so I can get right to it when my buddy gets back from vacation, or drive it around until he's back. I'm inclined to do as much prep as I can now, we'll see.
Finsihed up the Carrera bumper trim on the front bumper today. And I put the bumper guards on as well. I REALLY HATE those things on my car!!! I may end up taking them off, they just don't 'fit' the look anymore. If I can make new bumper brackets to get the rear bumper to come out more, and get the ride height so the body isn't so vulnerable to new car bumpers going over the speedster ones, it just may be OK. Again, we'll see.


On a side note: Bob Rose, are you still interested in my 1600cc? Wolfgang, are you still interested in the trans? Let me know and I'll get you a ETA for pick up/drop off on those.

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S schu
Mickey,
If Wolfgang ( Greg ) passes I would love a shot at your gearbox (Mine just blew up ) - I only live about 30 miles south of Greg and can plan a pickup date if it works out - I would love to see your car as well - I am looking for all kinds of ideas for my rebuild and love what you are doing to yours.
Greg?


Thanks,
Dale
FM Former Member
Guys, Mickey is pretty much always down on his car and its overall appearance, horsepower, turn radius, crappy seats, broken windshield ... or whatever. I have to say, without even the qualifier that the car's almost as old as Lane is, Mickey's really got something in that IM.
This is one of those cases, rare cases, of a man who's truly, passionately, in love with an idea. We all know that a car is just a car, but we all also know that these little jobbers hold a place in the family.
Mickey's one of those guys, with one of those cars. I'd also have to say he's one of the most genuinely down-to-earth people I've ever met -- and it's more than worth it to troupe up (or down) I-95 to run the back roads with him.
Take the time, if you have it.
M mickey356
Too kind Cory, too kind.
It's true. I am always beating up my little car for not meeting my standards but this time around I imagine I will get what I've always wanted from it. I'm committed to doing it right, at least for me. I have brushed the issue of time aside and will leave nothing out until it's completed.
I can't wait to see that engine sitting in my engine bay! I can't wait for the first time I pull out and open it up. And I can't wait until I put that last finishing touch on it. As I've said before, my hopes are to have it all done for Carlisle next year.

I'll keep you all posted on the progress. I don't imagine there will be much in the next 2 weeks, but after that look out!
L lambros
Mickey

I keep reading all your post about your project and can not wait to see the final result. Have you decided on wheels yet? I know you like the "wide 5" look, but have you thought about the 5X130 pattern using spare wheels out of 944's? You have to drill, but you will have the "original" look.... other than the wide 5.
If you want to see picture of one let me know and I will e-mail you a picture.
FM Former Member
Has anyone noticed that those aluminum 944 spare wheels look like the four lug VW Marathon wheels?

Not aluminum, of course, but visually a pretty close ten spoke match.

944 wheel:
http://www.thesamba.com/vw/classifieds/detail.php?id=651644

VW Marathon wheel:
http://www.thesamba.com/vw/classifieds/detail.php?id=559062
Gordon NicholsGordon NicholsMassachusetts 1993 CMC Supporting Member
Mickey:

That's how Chris and I got started welding; I bought a Century welder at Sam's Club and used it to build my car. Unfortunately, I never really did enough with it to become proficient, even though one of my Navy Sea Bee uncles taught me the basics and then told me to "Practice, practice, practice!"

Chris, on the other hand, went nuts with it, welding up all sorts of things for himself and his friends. As he went along and welded more and more stuff, his welds got better and better, culminating in a car-hauler trailer which is now mine. It looks (and hauls) every bit as good as a commercial (like Kaufman) trailer, and I'm proud of it because he made it!

He's now graduated to a commercial Miller welder, and still welding a lot of stuff!

gn
DUBSTUBDUBSTUB
Mickey
We need more pictures of what you have done so far. Get the camera out and start posting. I know how you feel, my car is almost done. When I get home, I will take it back to the paint shop to buff out some imperfections and then finish the script and the bumpers. I still haven't talked to JPS about how he does his. Let's see some pictures of yours, when you get it fixed. Sorry you have to park in the street. That sucks. Oh, and be nicer to your elders.
Warren
M mickey356
Warren,
I promise I'll post some pics soon. I haven't really done much other than the rear narrowing and the wide 5's back there. Other than that it's been the bumpers and little things here and there. The front bumper trim went on very easy. I drilled the holes, slid the flathead bolts in the channel and then I just attached the trim to one bolt on the end off the bumper. Then I gradually formed the trim around the bumper attaching each bolt as I went along. I just cut the excess off the ends and filed them down. I still have to polish the trim but I wanted to get them on the car asap.
I'll post pics of the body reinforcement and engine and trans swap in a couple weeks when I get to work. I also have to install the new lid while the motor is out.
I did take the rocker panel trim off and fill the holes. I did a quick sand and rattle can job on those areas and on the deck lid. I'm going to do the 'real' prep next spring just before paint.

Dale,
I'll pm you about the trans.
M mickey356
TC,
The interior will be the last thing done, probably next spring. But since you ask, I plan to have the seats redone like the pic below. I'll either buy new guages, or use the ones I have and get them refaced to show proper mph and rpm. I'll be refinishing the dash this winter at which point I'll install the 'dual ignition switches' which won't be functional, just for show. I'm putting a steering column support ring in as well. New carpet also. The one thing that will just eat and eat at me is that F'n emergency brake! I've looked into the Lokar under-dash unit but I don't think I have to skills to install it properly. I'll figure something out though. I think the main problem with that is the rerouting of the cables. So I may see if it can be mounted under the center of the dash directly above the tunnel. Maybe that way it won't be such a chore, but I don't know how visible it'll be, or if it can even be mounted there.
So dig deep and see if you can find that opinion, I'd love to hear it.

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MusbJimMusbJim'14 VS SoCal Supporting Member
Mickey -

Since you're doing the dual-ignition thing for 'show' - apply the same philosophy for the handbrake.

Remove the tunnel-mount handbrake you have and replace it with a hydraulic switch like Kelly has on his car (I think it can be hidden from view under the driver seat) - then mount a pseudo-umbrella non-functioning handbrake under the dash (for show)?

...I'm just saying...
FM Former Member
Mickey, you should be able to use cables for the under-dash brake, but you're thinking like a purist.
The same place that can make you a longer cable -- a boat shed -- can hook you up with pulleys like sailboats have for the angles it'll have to follow.
Block and tackle systems aren't hard to figure out. I'll help.
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