Odd Projects

Here is a collection of odd projects on the Hippo:

I discovered one of the bypass pipes wore a hole in the heater crossover pipe:

So I took a stainless washer, bolt and nut, and used our friend, JB Weld, to cover the hole:

A second stainless washer was bent to fit against the pipe, and put in to place:

 

Here's Harald Jülicher removing the airbags:

And my Duct Tape Engineering replacement:

 

I've always disliked the black bumperettes - it's a carryover from my '87. So for fun, I primed and painted the rear bumperettes to see how they would look:

Eventually they will be deleted when I make the trailer hitch mount.

 

I hate Cosmoline! So a bit of pressure washing and citrus solvent to start chipping away at 9 years of gook. I like a clean engine/undercarriage both when I'm working on it and as a preventative - you can see the early stages of a leak or other problem. The primary purpose of this wash was to clean out the suspension areas in preparation for the upcoming KMS/Penske shock install.

 

I installed WEVO Semi-Solid Motor Mounts:

 

Took out the fog lights, painted the center bar and the bumperettes:

 

Battery Hold Down

I picked up a sealed Odyssey battery. Lighter, smaller, better. But it needs a mount to hold it in place. So I hacked together a mount using some scrap aluminum sheet and some hardware. After making a template, cutting the aluminum, etc., here are the parts:

 

This is what it looks like put together:

 

And the lower mount in the trunk:

 

Tah Dah! Saves about 10 pounds, plus having a sealed battery is always nice. When we go to Phase III I'll move it to the centerline in front of the gas tank.

And here is the "new and improved" version with a bracket at the base to prevent sliding and viny hose around the top clamp for insulation:

 

Headliner

After removing the sunroof box and welding the cover panel in place, I needed to cover up the bare metal roof. It didn't make sense to spend $750 for a factory headliner -- which probably wouldn't fit with the main hoop of the cage. So I did the impossible - a sheet of vinyl, a can of glue, and I have a pretty tacky looking headliner:

Well, it does the trick...

 

DME Relocation

In preparation to install the 6-Point harness, you have to mount the two sub-straps under the seat. But this is what is under my seat:

That's the DME (Digital Motor Electronics) or ECU - the computer that runs the car. It is absolutely right where I need to drill a couple of holes and mount the harness eye bolts. After much pondering of ways to make brackets that attach to the seat mounting points and other less desirable alternatives, I decided that to do this right, I needed to relocate the DME. The sub strap mounting position is a very important part of the safety package -- this is the wrong time to compromise.

After more pondering of where to relocate the DME, the cable harness was the limiting factor -- how far can I move the DME without cutting wires. I try my best to follow the Hippocratic oath when working on the car (especially with electronics): First Do No Harm.

I wanted to mount it vertically on the panel in back of the rear footwell, but a) the harness really wouldn't reach; and b) there are brake hydraulic lines right there (remember the oath - drills near hydraulic lines are bad). I could just bolt it to the floor pan - but that's in the flood zone and anything that might hit the bottom of the car might hit a very expensive box of electronics. So I decided I could simply reverse the existing mounting plate. Just cut off a piece, attach it to the floor pan with a riser, and bolt everything back down. I thought this might look reasonably "factory like" as well.

Here's the empty rear floor area with the riser (I also installed a new floor pan drain).

And with the mounting pan attached:

And finally with the electronics back in their new home:

 

For the passenger side, I just cut a big hole out of the mounting pan, then protected the edges with with tubing:

 

Sub Strap Mounts

Here are the pictures from the installed sub-strap mounts:

 

Ultralap Mounting

First, I mounted the receiver unit on the roll cage. Gary Ozzborne from Trackday Motorsports supplied his new custom clamp. They are well-made and bolted right up. I picked up two, one for each side so I can just snap out and snap in the receiver depending on which side of the car the transmitter is on.



Looking around the dash, the best place where I should be able to reach the display unit while in the harness was around the location of the ash tray. I thought about a temporary ashtray bracket like Gary supplies for older 911's. Since my car is mostly track duty, a semi-permanent mount made more sense to me.

I decided to remove the ashtray and mount the display in its place. I took a piece of sheet aluminum, and using the Mark 1 eyeball, bent it to attach to the two existing screw holes from the ashtray. I then bent the piece to give the display an angle towards the driver. A little primer, a little paint, and some extra vinyl to cover up the end that shows, and you have this:



The white is the double-sided velcro for the display.

Well, there's this big hole under the mount. I thought briefly about putting the ashtray back in, but it probably wouldn't open nor would you have access to it, so it stays out. Another piece of sheet aluminum, some bending, and another piece of scrap vinyl - a blank plate:



The ashtray is next to the plate for reference - the angle makes the plate look larger than it is..

Here's the driver's view with the display mounted:


Mounted a fire extinguisher on the driver's side sill:

 

I'm vertically challenged. So I made pedal blocks to bring the brake and clutch a little closer:

 

And sealed the sunroof:

 

Spoiler Wall Repair

The spoiler wall is a weak point in the 993 design. The living hinge typically splits, and with 10 years of up and down, mine is no different. It's not an expensive part to replace, less than $100, but in the next year or so, I'll be replacing my decklid with a fixed spoiler. So a repair, even if it works for only a year or so, was in order.

I simply riveted four small hinges in place:

Then using some black reinforced duct tape, covered up my handiwork on both sides:

 

Repainting the Wheels

After seeing an identical white 993 at a local autox a few weeks back, I decided that the shoes needed some polish. So I took the opportunity to do a little sanding and painting. As with everything on a track car, they look great from 10 feet away (or on the web) - since they will get nicked up, I didn't go for a concours finish.






To sand down the rim, I mounted the wheel back on the front axle and spun it with my left hand as I sanded with my right. After a few hours of that, I nearly crippled my back. In a flash of inspiration (but a day too late), for the final sanding I took the brake pads out, and spun the wheel using a drum sanding pad on a drill. Doh!

The rears are pretty big, so I just rolled the fenders. Couldn't find a bat anywhere. So the benefit of it being a track car is I just got in there with a big
socket on an extension and cranked.

Some close ups of the wheels:


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