1/8 Porsche 935/78 'Moby Dick'

No problem! I stopped keeping a record of build-time when I did the 908-3: I knew it was going to take a long time, so didn't want to get depressed! I think the 917-10 took around 1200 hours over two and a bit years, and the 908 was a little over three years...so maybe 1500 hours or more? I'm having to spend more time 'designing' the 935 as I don't have much in the way of official drawings to work from. I don't mind the time spent on research as I have been collecting info for several years now - when the model is finished and gathering dust, I still have the books to enjoy!

I actually have an airbrush and compressor, but I would find it hard to use it for most of the painting I do. It might get more use on the 935, though, particularly on the bodywork and interior. I think part of the problem is that airbrush painting is something I only do once every few years - everything I learnt when I sprayed the 917-10 in 2008 has now been forgotten! Must practice more often....

Here's the first 917K I made back in 2004 - 2005...with all the info I've got now I could make another one with much better detail, but I don't think I could go through it all again!

http://www.automotiveforums.com/vbulletin/showthread.php?t=941669&highlight=1+8+porsche+917

i hope you will use your airbrush this time, cause it will make a big difference in modeling ;)

If your in trouble with 2k Laquers, fell free to conatct me, as professional car painter, i think i have some tips for you on the go ;)
As usual, nice progress!! :top:

Thanks for the offer, GP - it'll probably be next year before I'm thinking about painting anything, though!

I've spent this week refining the components for the front struts and hubs. The new hubs are slightly shorter than the prototype (18mm long) but are still based around using several sizes of styrene tube to get the required shape. The innermost tube is cut away to create the two clamps which hold the hub to the strut, with extra detailing from the half-round sections. The three thick rings are cut from two sizes of tube glued together, then trimmed to suit.

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby258.jpg

Here you can see the two hubs assembled. On the right, one of the 'ears' is offset - I've added a small bush to each hub to provide a base for the steering arm, which will be added later.

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby259.jpg

I've also re-made the struts, using a combination of styrene, aluminium and brass tube:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby260.jpg

Switching to ali tube for the sliding sections gives me several benefits. First, it allows me to make the top part of the strut in a slightly smaller diameter, which looks more to scale - but it still fits in with the styrene. Also, it avoids problems with paint getting rubbed or scraped off later in the build - I can polish the ali instead. Finally, a length of brass tubing added to the inside keeps the strength up.

Finally, I've made a start on detailing the 'front' side of the hubs. I've glued small pieces of curved styrene to create a core, then addded greenstuff to get the shape of the lugs. When this has hardened I'll give it a final fettle with file and wet'n'dry. I'll be adding some small hex-nut detailing to the other sides of the lugs, too.

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby261.jpg

Once all that's done I can work on the housings for the stub-axles, caliper lugs, etc.

That's it for today - more next week.

SB

SB.
First post here after following the latter part of your 908/03 build and now Moby too.
Just thought that you and others following your scratch builds may be interested in sugru. Not used it yet but have some on order to try out Amazon.co.uk).
From the website:- sugru is the exciting new self-setting rubber that can be formed by hand. It moulds like play-dough, bonds to almost anything and turns into a strong, flexible silicone rubber overnight.
http://sugru.com/about

By all accounts it remains flexible when cured; which may be useful later in the build when you get to detail parts? I'm sure we can all find uses for it but thought you may have a wider audience.
regards Neil

Excellent! I love the small bits,

ianc

Hello again,

It's a double-size post tonight to make up for last week! Last night I was busy listening to the closing stages of the Rolex 24 at Daytona and had got into a groove with the modelling, so decided to do the update today.

So, here's the next stage in the construction of the front uprights. I've applied greenstuff to all the lug detailing and given it an initial shaping with the file. To mount the stub-axles to the main body of the upright I've built up a central spigot which is pinned through the double-skin. The stub-carrier section is sized to take a 5/16 capscrew (with the head turned down) which will form the basis of the axle - but with more detailing than last time!

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby262.jpg

Next, I wanted to work on the lower wishbones. I'm using RC car balljoints again, and these are pinned onto 1/8" stryrene tube. To bulk-up the rear arm of the wishbone, I'm adding two lengths of shallow channel section, which will eventually be greenstuffed and shaped to suit - the strength remains in the central tube, though. In time I'll add a small bracket to each arm to connect the front link - the Moby's wishbones are not one-piece.

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby263.jpg

In amongst all this I've CA'd the ali sleeving into the strut tubes so that I can do a basic assembly of the suspension:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby264.jpg

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby265.jpg

The uprights are still free to move on the strut so I can adjust the positioning, and there's scope to tweak the wishbones too. You might just be able to pick out some of the hex-nut detailing I've added to the uprights, too.

Before continuing with the suspension components, I wanted to reinforce the mountings. So, I added a few gusset plates:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby266.jpg

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby267.jpg

Most of the work in the last few days has been focussed on the steering rack mounting. This structure will connect the two rear pick-ups of the wishbone, and once it's done I can start thinking about the rack itself. First step was to fit the two diagonal chassis tubes - the longer one had been cut and trimmed some time ago - but I added some ali reinforcement inside too. Next was a pair of triangular blocks connectd by a length of 0.75mm stryrene sheet - this is the core of the structure:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby268.jpg

Now I could start filling in the gaps. To give a little more depth to the plate detailing I glued thin slices of styrene tube to the inside faces to create the impression of swaged holes:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby269.jpg

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby270.jpg

...and the view from the back:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby271.jpg

Two small plates fill-in the top of the structure; I added some small styrene pieces inside to give these plates something to sit on:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby272.jpg

Finally, I've started adding plates to the back of the structure - this is not quite as simple as the front face, as I'm having to work with all the different angles:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby273.jpg

So, this should be finished off during the next few days, and then I can add some greenstuff all over to fill in the gaps and give it some extra detailing. I've painted the inside of the structure during assembly, as it will be a pain to get in there afterwards - although once the model is finished, you won't see any of this as it will be buried beneath the fuel tank...

That's it for tonight - all up to date. It's actually been quite refreshing to get back into some proper detail work, and the front of the chassis is suddenly looking a little more realistic. I'm going to have to start tackling the wheels soon, though...

Neil - thanks for the Sugru reference. It's not something I've tried myself, but it could have it's uses. As you say, might be worth getting some and giving it a go!

More next week,

SB

Another great update.

Amazing!! Is posible to have a picture of the complete work, in order to know how it goes?
Thanks in advance!!

Back to normal this week...

First job was to continue with the rack mounting structure - I added the final panel to the back, and started applying some greenstuff to fill the gaps and give some welding details:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby274_zpseb89385d.jpg

It needs a little more work, but it's looking how I want it. I'll post a photo of the back view next time...

I then returned to the front suspension - the four inboard pivot 'rod ends' were made using my usual technique of wrapping and twisting thin wire. I'm tempted to try bulking them out with a little greenstuff, too, so we'll see how that goes. Then it was a case of checking the geometry, making a few adjustments, and adding some brackets to connect the forward stays to the wishbones:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby275_zpse2d7521b.jpg

More greenstuff again, to tidy up the main wishbones and to fill some of the gaps on the uprights:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby276_zps4165fab1.jpg

Finally, I made a start on the steering rack. The main casing will have a further length of ali tubing fitted inside, with the 1/8" diameter rack bar (also ali) inside that. I'll make some separate ends later to give the look of the rubber boots. The mounting blocks are an integral part of the rack casing and have been made from a length of 1/8 x 1/4" box-section with extra styrene added on top. The other components you see here will form the pinion housing :

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby277_zps347195b8.jpg

I'm hoping to get this all together during the next few days, then I'll have to make some clevis ends for the main rack bar, etc, and work out how to connect everything to the uprights. The steering column itself is a job for another time - it has to snake it's way up the front bulkhead, and until that's done, there's no need for the column!

So, that's me up-to-date again. I've bought myself another cutting mat (A2-size!) as my old A3 version just gets covered in rubbish. I'm now wondering if it's possible to replace the carpet in my room with cutting mat material, then it wouldn't matter where I worked! Hmm, best not to, I think...

Have a good week, everyone.

SB

As always great progress you show us SB.
I just love seeing the parts grow in the palm of your hand. You have a special formula for that ? :grinyes::grinyes::rofl: Just kidding...
Thanks for sharing your great skills with us.
I'm curious too what you've got in store for us next time.

Mark

Hello again...

Continuing with the steering rack, I added two pairs of styrene collars around the pinion output, then applied the greenstuff to smooth it off:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby278_zps79b14947.jpg

The greenstuff was tidied with a file and then the rack could be assembled, making sure that the pinion output was at the correct angle to suit the bulkhead. I added a little extra detailing with styrene and greenstuff to fill in the gaps, then drilled two small holes in the base of the mounting lugs so I could pin the rack in place:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby279_zps10ccc340.jpg

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby280_zps5d70686d.jpg

I haven't got around to sorting out the end detailing for the main case yet - the styrene is prepared, I just need to attack it on the lathe sometime.

Next, I switched to the top mounts for the front suspension. Although the 935 will not be sitting for any length of time with all it's weight on the suspension, I want everything to be secure - I don't want bits getting knocked off every five minutes while I'm building. The chassis frame pinning has limited how far I can pin the RC balljoints into the crosstube, but it's enough to give me a starting point. I glued these in place and set to work on making some styrene reinforcement:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby281_zps2e4ccb30.jpg

The baseplate here is 0.75mm thick styrene, and with the strip detailing glued in place, I trimmed back the base to match the outer profile. Here it is on the car:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby282_zpsaab14a20.jpg

I glued more thin styrene strip underneath, then added another layer of 0.75mm to create the next step of the mounting. This will then have two vertical sections added to it to complete the structure - here I've added the first:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby283_zps51d5f9e1.jpg

There'll be more greenstuff added later to fill the gaps, and some extra tubes into the chassis frame. Hopefully the whole lot will be capable of surviving the rest of the build! One complication with this work is that the upper frame section has to remain removeable, so I have to be careful when I'm gluing - mustn't get carried away. So far, so good...

That's it for tonight - more next week.

SB

Again great progress SB.
I especially like how you do the fabrication of those little bits and pieces.
I can keep looking and reading for hours in your topic.
Keep fascinating us with your great skills.

Mark

Beautiful work on the steering rack. I'll bet you're dreading the U-joints for the steering column... ;)

ianc

Evening all,

More on the front strut top mountings tonight - first, I added the vertical reinforcing plates, then the two short lengths of tube to tie the tops of the frame together:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby284_zpsd205b200.jpg

I then added some thin strip along each of the verticals to create the impression of a folded edge, then applied some greenstuff to fill the gaps and show the welding:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby285_zps617ce6d3.jpg

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby286_zps8ddec20f.jpg

I've also fitted the top two stubs for the X-frame which drops into the nose of the chassis - they're pinned and glued for now, and will be greenstuffed next time.

Moving to the back of the car, I spent some time working on the rear dampers. The main body is 1/4" styrene tube, with various sizes of ali and brass rod sleeved inside to create the rod, etc. As usual, I've made and modified the first one as I've gone along, but will have photos of the components next time when I make the second unit!

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby287_zps122af3a1.jpg

The tricky part is juggling the top and bottom mounting points, whilst making sure there's clearance for the driveshaft (which I'm not even thinking of making any time soon) and keeping the damper at a suitable length. I've added a temporary mounting point to the back end of the trailing arm (which is sitting at ride-height) just to give me something to work with, but this will be replaced with a final version when I know everything fits:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby288_zpsdfe3935a.jpg

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby289_zps511492a4.jpg

The top mounting is now on it's second version - I'm trying out some variations on cutting the bracket from a length of 4.8 x 7.9mm box-section, and it might go to a third spec before I fit it to the frame. When I've got it all where I want it, I'll start making the second set of components for the other side.

Hi Ian - yes, the column joints could be fun, but one plus-point is that they don't necessarily have to be fully functional! I have a feeling I'll be fiddling around with a pile of thin strip and solid-section and making something that looks about right. To be honest, I've not given them much thought so far - I'm trying to focus on the frame and the suspension.

That's it for tonight - more next week.

SB

Coming on well.

Hello again,

First up this week is more detail on how I put together the rear dampers. Here you can see the components for the shaft / eye section:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby290_zpse4728e9e.jpg

Note how the ali shaft has a brass tube core, with a pin inside that which actually goes into the top loop. I'll add greenstuff around the spring collar to tidy it all up, too. Inside the eye of the finished shaft you can see a small black ring - this is a very short length of wire sheath which allows the damper some movement once it is fitted in place.

Next, the main body of the damper. Again, everything was sleeved down from the main 1/4" outer body, and the bottom eye pinned securely:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby291_zps258b88f4.jpg

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby292_zps0fbe79f2.jpg

This is as far as I need to go with these right now. I'll make the adjustable spring platforms in time, and also add some fine thread detailing to the outer body, etc.

I eventually settled on a design for the top damper mountings and CA'd them in place under the chassis beam. I added some small angle sections inside to reinforce them, then applied greenstuff all around - this still needs a little tidying up.

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby293_zpsb0e44a0c.jpg

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby294_zpsed38a07f.jpg

Finally, I returned to the rear trailing arms. The job now was to add the outer skins and bulk-out the core structure, whilst continually trying to improve the strength. As the outer shape of the two legs are tapered, not straight, I've added pieces of channel section to give the skin panels a solid fixing. The upper and lower faces will be filled with a combination of styrene and greenstuff...

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby295_zps33fb8221.jpg

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby296_zpscea06e5f.jpg

Once the two legs of each trailing arm are finalised I can sort out the proper mounting for the dampers. There'll also be some caliper mounting brackets to add later, and some small tags for attaching brake lines. Then I can think about the hubs, discs, etc and putting it all together...

Have a good week,

SB

Something that has always been on my mind while reading your posts:

Is it some sort of miracle that your clever use of Legos just happens to put everything in the perfect position? Unless you're taking some liberties in where things actually end up, I find myself unable to understand how it works out so well with *just* Legos. That is... unless the original 1:1 cars were built with scaled up Lego jigs, I guess. Hah.

That said, your work is absolutely amazing, and I learn so much every time I read one of your updates. Please, keep it up! You're doing great!

Incredible build! Just astonishing!

Hi Matthew,

Regarding the Lego, it's not a miracle - it's a combination of pure luck, the large scale, and the lack of official dimensions to work from. The challenge is making sure everything stays square and true, and for me Lego is the most convenient (and flexible) way of doing this. If I have to add small packing spacers to get the measurements I need, that's not a problem, but it's surprising how often it works out to an exact 'brick'. Many of the tubes are fitted freehand, of course, so it's not necessary to jig every single one - just enough to define the structure.

Of course, sometime next year when the engine and gearbox doesn't fit and the bodywork is all over the place, maybe I'll be thinking of a different technique for the next project...!

SB

Simply clean and perfect. Thanks again for sharing it!!

Hello again,

So, after adding the outer panelling to both trailing arms I set about creating the proper extensions for the damper mountings. The core for this was a short piece of 3/8" x 1/4", with a smaller piece sleeved inside, and 0.5mm sideplates:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby297_zpse832de71.jpg

The actual pick-up for the damper is fitted into the end of the trailing arm and is pinned through into the main bearing housing section - I can then use a combination of ali and styrene tube to attach the damper eye.

Here you can see where I've started filing down the two pairs of pins which strengthen the trailing arms joint with the bearing housing. Also, you can maybe just see where I've added some small pieces of styrene into the ends of the 3/8 x 1/4 box to fill it out:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby299_zps8abb8e1c.jpg

...and just to prove I've added the sideplates:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby298_zps44fefe1a.jpg

So, I can now re-fit the trailing arms and add the dampers:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby300_zpse4cc8715.jpg

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby301_zps21fb0142.jpg

The pins between the dampers and the trailing arms are a temporary fix - I don't have to worry about finalising these just yet. I could leave the arms as they are for now, but I want to continue with them and add the upper and lower surfaces - so that's the job for this week.

So far, so good...

SB

Hmmm...I'm slightly fed up now: this is the third time tonight I've started writing this update, and each time I've managed to lose it somehow before completion. So, it's all about getting the trailing arms greenstuffed; first, I added a few pieces of styrene sheet to fill some of the gaps:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby302_zps7316387e.jpg

Then, the first layer of greenstuff. It looks a bit rough, but it's easy enough to file and sand it flat afterwards.

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby303_zpsd21ccc40.jpg

I also added the small triangular extensions to the outer arm:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby304_zps641f06c1.jpg

Finally, here you can see some extra detailing - I've beefed-up the main pivot points, added the small crescent-shaped plate to the inside face of the arm, and the tube detailing on the other arm:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby305_zps3eb0e3d8.jpg

There's still more work to be done - more greenstuff detailing, caliper mountings, top and bottom reinforcing plates, etc - but right now they're complete enough to be able to move on to something else. Ideally, this would be the wheels, discs and calipers as I still want to create a rolling chassis before starting on the engine, gearbox or interior.

Next, I finished off the detailing for the ends of the steering rack. I'd glued the pieces of styrene tube together some time ago, and now added the taper to create the main body of the rubber boot:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby306_zps0af8743e.jpg

They were trimmed to length, and I then made the two small components on the right by layering together three pieces of punched styrene:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby307_zpsce9925b3.jpg

...and it all goes together on the steering rack like this:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby308_zps0ff725b6.jpg

This leaves just the rack bar, the end clevis' and the trackrods to make - jobs for another time, I think. I'm not too sure what I'll have to show you next weekend - hopefully something other than the trailing arms again!

Have a good week,

SB

Arms are looking great. I will have to try green stuff.:smile:

...on the subject of 'greenstuff', I've now got some new 'liquid greenstuff' to try out. As the name suggests it's a fluid version that comes pre-mixed - I've not used it on anything yet, but it could be useful for running into gaps, etc.

Anyway, back to the update. I decided to take the plunge and get on with making the brake discs; as with the 908-3 they're drilled and ventilated...only this time there's more holes. The 908 discs had about 20-odd rows of drillings, with four holes in each row...my 935 discs have 24 rows, alternating between five and six holes. So, that's 132 holes per disc face to be marked, drilled, and cleaned up, two faces per disc, for four discs. Let the drilling commence...

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby309_zps001c8416.jpg

I made this template in thin styrene sheet and will use it to mark each set of holes, hopefully making sure that I can keep the two sides of each disc aligned properly. The basic disc face was partially cut from 0.75mm styrene with the compass cutter, but not completely - I wanted to leave it attached to the sheet to make it easier to mark the holes. The template was taped in place, then the holes pricked through....and then I could start drilling.

Here's the two rear discs in their un-assembled state:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby310_zpsa8b38b7c.jpg

The inner fins are 10mm lengths of 1 x 2.5mm strip, with a slight chamfer on the outer end. They're glued in place not quite reaching the outer edge of the disc face - this is correct for the Freisinger rebuild. Before I glue the two halves together I'll paint the inside surfaces, but that's a job for later. I'm planning to add some extra detailing inside the back face of each disc, to show where the separate outer bell is attached, but I'll do this once I have all four basic discs cut and drilled.

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby311_zps1db8a3d8.jpg

...okay, slightly out of focus but you get the idea! There won't be a hub 'flange' as such as the disc will fit straight over the centrelock axle and sit against the hub carrier.

I've made a start on the front two discs and will continue with these during the week - this probably means I won't do an update next weekend as it will effectively be a repeat of this one! Making the discs like this is a bit mind-numbing, but the end result is usually worth the effort - it's good to know that once they're done, I won't have to do them again (until the next project!).

That's it for now,

SB

As usual, i'm speechless...
As usual, what an impressive work!
I'm waiting for the next update...

Sheeeeet SB!

I was about to suggest you'd need a decent dividing head and index wheel for that job - but indeed, YOU don't!!!

:smokin:

Seriously, I think there is a lesson to be learned from every one of your thread updates. I had been puzzling in my head how to create the disks for a 1/12 build I am in the early stages of planning and you just answered everything for me. Thank you!

Just the usual splendid craftsmanship... ;)

ianc

splendid attention to detail!

Back again...

Once I'd made the second set of disc components I was looking at how to take them a little further. So far - other than the number of holes - they're no different to the 908's...but I could see where I could add extra detail. As the discs are a two-part design with a separate bell, there is a ring on the inside face where everything bolts together - once everything is assembled you're hardly going to see these, but I thought they should be there:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby312_zps2d2b8138.jpg

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/05b6af9c-ae08-450c-babc-17fb86e0c135_zps9a23c0f4.jpg

I've also added a set of ten larger holes to each disc - these remain partly visible once the outer bell is added later.

Before gluing the two drilled faces together I wanted to add some colour to the inner faces of the discs - it would be easier to do this now than later. So, a black undercoat followed by a light drybrush with Boltgun Metal and Shining Gold:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby314_zps76646e8e.jpg

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby315_zps265cfb70.jpg

I've been careful to keep eveything marked so I can get the correct alignment, so it was easy enough to glue the discs together:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby316_zps4ac42ef4.jpg

I wasn't able to paint the inner surface of the top disc before gluing, but this won't be such a pain to do now. The outer faces can wait until much later in the build...maybe I'll take them to Le Mans again!

This weekend was a good opportunity to spend some time preparing for the next stage of the build. I've been putting off tackling the wheels for some time, but with the discs and suspension coming together it was going to start causing a bottle-neck - so I made my final calculations for the diameters I wanted and drilled four holes in my foam block with the adjustable cutter. Each wheel would be made from three main parts - the inner and outer rims, and the centre. The rims would start as three layers of 0.5mm strips, cut to length to get a snug fit into the foam block, then glued together - this was how I spent most of Saturday afternoon...

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby317_zpsb3e8d55d.jpg

I wanted the centres to be 3mm thick, so this was easy enough - two outer skins of 0.5mm, and a 2mm spacer in between. I coiled three strips of 1.5 x 2mm to give a solid outer edge, then filled the centre with a stack of discs which were left-overs from both the 917-10 and the 908-3 projects...I was hoping to find a good use for them sometime!

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby318_zpsa2f9e67f.jpg

For now I've only made two centres, one each front and rear - this will be enough for me to continue with sorting out the hubs, disc bells and brake calipers. There should be plenty of room with the rears, but the front wheels are that much smaller - but it should be okay.

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby319_zps4569692c.jpg

Clearly there will be plenty of extra work required to get these looking as they should, but it's a start. The centres will not be fully detailed, for the simple reason that they do not need to be fully detailed (okay, and a set of spoked BBS rim centres is too much for me to contemplate...). Any detail on the outer face of the wheel centre will be completely hidden once the fibreglass cooling cones are fitted...so that's my get-out-of-jail card. Please, don't give me a hard time over this...!

So, there's now plenty of things I can be getting on with over the next few weeks - the calipers alone will probably take two or three weeks to sort out. The tyres will be cut from foam again, but not for a while - they're quite vulnerable to getting chipped, marked or otherwise damaged, so they really don't want to be hanging around for months.

That's it for today - should be back to normal next weekend.

All the best,

SB

Masterclass!!!

Once again SB words escape me!!!!!!
You are a true master
John

Thanks guys - I'm trying to work out a few twists on some of these parts so it's not just a straight repeat of the last build. Keeps it interesting for me, and hopefully for you too!

This week it was time to start on the brake calipers. Normally I would create the basic shape by layering styrene parallel to the discs, with suitable box section in between to connect the two sides. After studying the Freisinger photos it was clear this method would not work - there's too much 'shape' on the '78's calipers! For example, instead of the inner edges of the caliper nearly touching the disc surface from top to bottom creating a narrow slot, there's a distinct tapering which make the opening more diamond-shaped.

So, this time I decided the way to go was to layer the styrene across the disc, parallel to the axle-line. Rather than jumping straight to the finished items I spent some time making a prototype caliper core, just to see what might be possible - it started with two 0.75mm thick plates cut to fit around the disc:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby320_zps1682cfe8.jpg

These could then be spaced apart with suitable box section, with more styrene added to fill the top and bottom openings. The curved outer surfaces could be created with greenstuff, as usual, with fine detailing added to finish them off - outlet ports, reinforcing webs, etc:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby321_zps0d7bbfb5.jpg

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby322_zps8d9d6f82.jpg

Normally I would make the brake pads as part of the main caliper body...but this time they'll be separate components which can be slotted into place. I've been checking the size of the caliper against both the front wheel rim and on the rear trailing arm (where it has to fit inside the damper pick-up) - so far, so good.

Happy that this method would work, I made templates for the two 0.75mm plates and started on the 'production' calipers:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby323_zpsbf257d16.jpg

The two plates are separated with lengths of 1/4" x 1/8" box section, with an extra strip of channel inside - this creates the gap for the pads. The angled pieces top and bottom are cut from 3/8" x 1/4" box. You can see from the caliper on the right where I've started closing off the ends of the central box-and-channel sections - this is where the brake line pipework will connect.

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby324_zpsabc96c15.jpg

The angled corners of the two 0.75mm plates will be rounded-off eventually, once the outer surface has been built-up with greenstuff. There's also a little more structure to add to the back face surrounding the opening for the brake pads - this will start with short lengths of angle.

Although all four calipers are basically identical, I didn't want to launch into making both pairs together - so I'll probably get these two to a suitable point before playing catch-up with the others, before adding the greenstuff and final detailing on all four later. As usual, all plans are subject to change...!

Have a good week, everyone,

SB

Very good ScratchBuilt: your work is an example for me...thanks

wow. even the pads slot into place. now that is excellent detailing there :)

Great, great work-awesome

Aawweessoommee

Fantastic!! No more words.

Another great update

Hello again,

Today has been motorsport from start to finish - Chinese Grand Prix at breakfast, an hour or so playing Forza 4 mid-morning, then 6 hours of WEC from Silverstone courtesy of Radio Le Mans (whilst I was modelling). Next weekend I'll be off to Brands Hatch for our first two FF2000 races of the season, so I've only got the next few evenings to continue making progress....

However, progress is definitely being made. First job of the week was to add some extra styrene plates to the caliper bodies, and fit the small angle sections which will help to create the 'overhang' either side of the pad slot:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby325_zps1b846218.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby325_zps1b846218.jpg.html)

I added several strips of small angle section to give the outer faces of the caliper some curves - and to give the greenstuff something to key to:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby326_zps331bbdf4.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby326_zps331bbdf4.jpg.html)

Here's the result:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby327_zps269236e0.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby327_zps269236e0.jpg.html)

I've left the bottom half of the second caliper exposed - this will be my reference for the second pair. I decided to continue with the other one so I would hopefully have something interesting to show you tonight! So, the next job was to attack the greenstuff with emery cloth and file to get it into shape. The fin detailing is all 0.5mm strip - a bit fiddly to glue in position, but it has to be there. I've given the outer caliper edges an initial filing to remove the corners, but I'm not totally happy with the shape - I think this will need more work.

On the other side of the caliper there are two large plugs with a recessed hex-socket - creating a male hex is no problem, but how do I make a female hex? The answer was prompted by thinking about Richy78's 'Black Widow' 936 thread, and how he made a punch to create the headlight and duct shapes. So, I added two thin rings to create the outer edges, then filled them with greenstuff - a piece of suitable hex-rod styrene was pushed into the greenstuff, and this was the result:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby329_zps3dff12bb.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby329_zps3dff12bb.jpg.html)

Thanks, Richy78! I let the greenstuff harden overnight then filed it to the correct thickness this morning. As you'll see, the inner face of the caliper is 'snug' against the damper mounting on the trailing arm.

Another quick job was to make a prototype brake pad - these will be a 0.5mm backing plate, with 2mm thick strip glued together and shaped to create the friction material. It needs refining, but the idea works - there'll be some retaining clips added to the caliper to hold the pads in place, too.

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby330_zpsc98f3d07.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby330_zpsc98f3d07.jpg.html)

By this point I'm starting to feel quite happy with how this is turning out - there's still more detail to add, but the basic shape is right. To mount the calipers I would need a pick-up on the trailing-arm, and a pair of lugs on the caliper itself. Rather than relying on glue to hold everything together I decided to pin the caliper to the trailing-arm - the pick-up would disguise the pin, and the caliper lug would be decoration, rather than functional.

I used a 14mm length of 1/4 x 1/8" box to create the trailing-arm pick-up, filed to suit the curve of the hub carrier section. A smaller piece of solid styrene was glued inside, then drilled through:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby331_zps892b7495.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby331_zps892b7495.jpg.html)

All I've got to do now is make some lug plates for detailing to slip between the pick-up and the damper mounting. It's not obvious from this final photo, but the hex-socket detailing on the side is virtually touching the damper mount -no problem, though!

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby332_zps791e3b2b.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby332_zps791e3b2b.jpg.html)

I'll work out how to mount the front calipers in a couple of weeks - during the next few evenings I'll start making the basic components for the second pair, then work on getting all four to the same level. I doubt if I'll have anything 'new' to show by next weekend, though, so don't be surprised if there's not a major update until the end of the month.

Have a good week,

SB

Thanks for the update Christian. You mentioned Forza 4 in your update....thinking about buying X Box and Forza 4 as I've come to dead end with GT 5 and the thought of racing the Flying Lizard Porsches is just too appealing. What's your thoughts on Forza 4 -vs- GT5??

Regards Rick H

Fabulous work as usual,

ianc

I like that, very good.

Evening all - back again.

Although it's a couple of weeks since I posted, I've been busy getting all four calipers brought up to the same level - and making progress in one or two other areas, too.

Firstly, I made the second pair of panels for the caliper bodies, added the box-section spacers in the middle, and used one of the first pair as the pattern to add all the plates and ribbing for the greenstuff:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby333_zps810b156e.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby333_zps810b156e.jpg.html)

Once I'd got the main caliper bodies sorted out, I wanted to make sure I could create a strong mounting on the front uprights, as on the rear. To provide room for adjustment I used a 3mm thick ring, to which I could attach the mounting bracket and pin through the whole lot into the caliper - the ring would slide over the hub-carrier and could be fixed in place to suit:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby334_zps498d23cd.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby334_zps498d23cd.jpg.html)

As before, the mounting bracket started off as a 15mm length of 1/4 x 1/8" box, with plenty of filing to fit the centre ring. The second mounting is not used, but as it is visible on the car it required extra shaping. After gluing everything together I used a little greenstuff to smooth the transition from the ring to the mounting:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby335_zps8007ac3e.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby335_zps8007ac3e.jpg.html)

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby336_zps84c9ea85.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby336_zps84c9ea85.jpg.html)

I've also made a couple of slightly thinner rings to add to the outer edge of the hub-carrier - these will give a little extra support to the brake disc assembly.

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby337_zpsba17e1ae.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby337_zpsba17e1ae.jpg.html)

The capscrew used for the stub-axle is not final! This is another area where I want to improve over the 908, but for now I just need something there to hold everything together and prove it works. So, all four discs have been opened out to suit the 1/4UNF thread, and I've made a couple of sleeves to fit inside the rear trailing arms to get the correct size.

Here's the front uprights, with discs and calipers:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby338_zpsa5d61b38.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby338_zpsa5d61b38.jpg.html)

Finally, I've made a start on making the eight individual brake pads. Took a while to decide which compound of styrene to use (serious stuff, this) and settled on the reliable 'Evergreen' white! I glued three lengths of 2mm thick strip together to create the pad, and used 0.5mm sheet for the backing plate:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby340_zps994cec47.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby340_zps994cec47.jpg.html)

...and to prove that they fit:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby341_zps553aadc4.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby341_zps553aadc4.jpg.html)

Now to make the other four, and create the retaining clips. The calipers are not finished yet - I need to add all the connections for the pipework, do a little more shaping here and there, and finish off the mounting lugs - but they're complete enough to work with . The last 'big' job will be to sort out the disc bells - then I can finalise the wheel centres.

So, the rolling chassis moves a little closer. I'm racing again next weekend (at Snetterton), so it's another opportunity to show everyone what I've been up to - they've not seen anything from me since I finished the 908. I want to assemble as much of the model as I can, so hanging on the four corners will certainly look good. Whether it will look like a year or so's work is another matter...

As always, have a good week.

SB

Looks great as usual SB! How are you making the hex head bolts for the brackets holding the strut to the hub?

ianc

Hi Ian,

For most of my hex-nut detailing I simply use small pieces of Plastruct hex rod cut by hand and filed flat where required - I bought six different sizes from Hiroboy a few years a go before I started the 908 (and fortunately still have plenty left, as I haven't seen it in stock there since!) The sizes range from 0.8mm through to 3.2mm hex (part numbers 90872 through 90877) and allow me to add the appropriate nuts where required. I'll often add small punched styrene discs underneath the nuts as washers, or to look like K-nuts.

I also keep an eye out for proper small-sized nuts, and will use these mainly on the oil lines, fuel system, etc (again, as on the 908). I've got a small stock of M1.6, M2, M2.5 and M3 nuts (3.2mm to 5.5mm hex) so these extend the range I can handle.

Sorry there hasn't been a normal update this weekend. Last week was particularly busy at work - I didn't leave the workshop until 10pm on Thursday as we were trying to get a car finished (Chevron Formula Atlantic), Friday we were testing all day and I didn't leave the circuit untill 7pm, Saturday was race-day with another 10pm finish, and Sunday was also race-day...finally finished at 7pm! So, not a lot of time for modelling...

Hopefully I'll have some new developments to show you this Sunday - I'm still trying to work out the best way to make the brake disc bells, given that I don't necessarily want to machine them from solid (you know - that would be far too easy!), so that's something I want to get sorted during the next few evenings.

SB

This build definitely deserves one of these: :eek2:

Hello again,

Lots of catching up to do tonight - I should have posted last Sunday, but ran out of time before the Nurburgring 24hr race started. I was going to post again last night, but had computer issues...so it's now or never! The problem is going to be remembering what's happened recently...

So, starting with the disc bells. My first attempts at these weren't successful, but gave me some ideas which would work out later on. The two main problems were being able to create the slight chamfer to the outer edge, and to put ten holes around the perimeter. My first thought was to build up the centre of the bell with various sizes of styrene tube, then add greenstuff around the outside to create the chamfer (with a little machining afterwards, too). How to create ten evenly-spaced holes around the outside? How about inserting short lengths of tube into the centre boss, then filling around them with greenstuff? Hmmm...neither plan worked as well as I wanted:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby342_zps4fe3097e.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby342_zps4fe3097e.jpg.html)

Plan B was to create the whole lot from styrene, with minimal need for greenstuff. I still used different sizes of styrene tube to create the core, but left the innermost section long - this would give me something to hold in the lathe:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby343_zps9bdd531f.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby343_zps9bdd531f.jpg.html)

To increase the diameter, I wrapped bands of 0.5mm strip around the core:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby344_zps3cccf087.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby344_zps3cccf087.jpg.html)

Before adding the chamfer / taper to the outside edge, I marked and drilled the ten holes. I measured the circumference, marked this out on a strip of masking tape, split the length into the appropriate sections, and that was my drilling template:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby345_zps8a656e2e.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby345_zps8a656e2e.jpg.html)

After opening out the holes, each bell was spun in the lathe and the outside edge gently sanded off to suit - not much of a taper, from a little over 17mm diameter down to 16.5mm diameter, over 5.5mm length. I made a total of six bells - I could pick the best four to use on the car, or have a couple of spares in case of 'accidents'...

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby348_zpsfdddcf62.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby348_zpsfdddcf62.jpg.html)

At this stage I could cut off the extra length of tube, then add an outer disc to tidy up the face - these were all drilled using a template (five holes for the locating pegs, five lightening holes):

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby350_zpsa05ac807.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby350_zpsa05ac807.jpg.html)

I've started messing around with the drive pegs, too. I cut a set of 3mm lengths of 1.5mm diameter ali tube, chamfered the ends, then CA'd each of them to a short length of .75mm rod. The trick is going to be gluing them into the bell so that everything stays true and in-line...the holes are not exactly perpendicular to the base...

Will continue this post after the break...

SB

Okay, the next job was to make some dummy tyres. I know I'd said I wasn't going to make tyres too early, but it seemed daft not to get something on the car to make sure everything worked and fitted! To make sure I won't use these as the finished parts I wasn't too concerned about the accuracy of the profile or the smoothness of the finish - they just had to be the right size and fit on the rims.

So, I used the adjustable hole-cutter to make the two blanks for the rear tyres - they'll end up about 48mm wide, so will just squeeze out of the 50mm sheet. Unfortunately the hole-cutter won't go through in one pass, so there's a bit of fiddling around to keep the two cuts aligned!

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby351_zpsf23f3bb1.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby351_zpsf23f3bb1.jpg.html)

The blanks were then mounted on a long 1/4" bolt and spun in the pillar drill, with a sanding block and emery cloth used to create the shape. With the outer profile complete, I could remove the centre using the adjustable cutter...end result as shown:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby352_zpsc052e621.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby352_zpsc052e621.jpg.html)

The front tyres are a little over 40mm wide, so before cutting and sanding them I milled the foam down to the appropriate width:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby353_zpsde9669cb.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby353_zpsde9669cb.jpg.html)

I used the same process to shape and cut the front tyres as for the fronts. Cutting the centres out was a little more...interesting...as the cutter was spinning away a little closer to my hand than I would have liked! No dramas though, and the foam is strong enough that you can hold it firmly without worrying about it crushing...

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby354_zps1ec47667.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby354_zps1ec47667.jpg.html)

At this stage I returned to building the internals for the rear wheels. The black centre tube is spigoted into the two 0.5mm discs which fit snugly into the wheel rim. I've then started layering more discs onto this to build up the edges and create the ring of split-rim bolt detailing. The five spokes are short lengths of box-section, cut off to suit, and filed to match the centre - eventually these will be filled with greenstuff.

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby355_zps69fa38b4.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby355_zps69fa38b4.jpg.html)

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby356_zps1478c514.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby356_zps1478c514.jpg.html)

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby357_zpsa8a18c67.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby357_zpsa8a18c67.jpg.html)

Now, you know what's coming next! I've got four rims, four tyres, suspension front and rear...and various bits of fibreglass fitted onto the chassis...

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby358_zps2960c522.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby358_zps2960c522.jpg.html)

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby359_zpsc35868ba.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby359_zpsc35868ba.jpg.html)

...yeah, I think it's looking like a 935!

The important thing here is that everything fits and nothing fouls the body - I was worried that the fronts would get too close to the fibreglass front wings, but the clearance should only improve as I start fixing the suspension in place. I can play around with the wheel offsets a little too, before finalising the geometry...then make the outer bodywork to suit.

So, there's still plenty to do but the goal of having a complete rolling chassis is coming closer!

Have a good week,

SB

Jaw-droppingly brilliant work SB. So many techniques to admire and copy, a veritable minefield of information and skills. I thought your 908 was brilliant but this is a tour-de-force of you imagination. I'm in awe.

Regards Rick H

How cathartic it must have been to finally be able to do a mockup on the frame! I'd being itching for a little paint right now just to keep morale up!

ianc

Hi Ian,

Yes, it's that moment when you start thinking 'this is going to work...' rather than 'I hope this is going to work...'! I'm forcing myself to keep to the plan of getting the rolling chassis sorted before starting the engine, gearbox, etc - otherwise I'll end up with a whole pile of bits in various states of completion. I have a feeling I'll be starting to make more bodywork moulds later in the summer - the temptation will be too great!

It feels slower doing it this way, but I know there's a lot of hours gone into the discs, calipers, trailing arms, etc, that weren't necessarily there with the 908. Painting and final assembly is not going to be straight-forward, either - it's much easier when there isn't a roof in the way...

SB

WOW.
What a master class in scratch building.
Plenty of posts voicing apprication , but I have to say thanks also for sharing.
If a modeler never tackled a total scratch build , there's some great WIP staged shots to "show you how to" scratch build a variety of parts and assemblies.

Thanks for putting in the the time into the photgraphs and text...It's time consuming I'd imagine but very much appricated.

Stunning!!! Now this is REALLY Building a model!!!

Now that is just going too far, excellent work and those tyres......OMG

Evening all,

Not a big update tonight - more a case of tidying up before continuing with the next big step.

First, here's the rear wheel centres after I've filled the spokes with greenstuff - they'll need filing and smoothing tomorrow once it's hardened. I also added the hex detailing to liven things up a bit - if they're supposed to be split-rims, they need bolting together, right? You can also see where I've drilled the five holes in the centre boss - these match up with the drive pegs on the disc bells.

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby360_zpsc241f85f.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby360_zpsc241f85f.jpg.html)

Next, I made the remaining drive pegs - they're not glued in place yet, just in case...

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby362_zpsbb22b28e.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby362_zpsbb22b28e.jpg.html)

Finally, the front wheel inners. These were similar in construction to the rears, only slightly smaller. The other significant difference is that they don't have the same offset as the rears - the centre boss is shorter. As a result, the five spokes are lengths of plain strip styrene, rather than cut-down box-section (to avoid fouling the brake calipers):

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby361_zpsc6bb17b5.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby361_zpsc6bb17b5.jpg.html)

So, once I've filed the greenstuff on the rear spokes I'll be able to start thinking about gluing the wheel sections together and adding the next stage of detailing. I'm tempted to make a start on the moulds for the aerodynamic wheel covers, although this could be easier said than done! The calipers still need the pipework, etc, adding so that's also on the to-do list.

Thanks for the recent comments - I realise that my methods are not necessarily appropriate for everyone, but there's always got to be an alternative way to do things! I think I've said this before - I'm trying to find new things to add to this build so that it stays interesting.

All the best,

SB

Always interesting.

No pressure, then...!

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby018.jpg

From this (above) to this (below).......amazing work SB. :worshippy :worshippy :thumbsup:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby359_zpsc35868ba.jpg
SB
I am so not liking this........ I LOVE'it. :aus:

Nice one, Greg! Although the cardboard looks rough, it has been very useful for mocking-up certain areas of the build, and getting a feel for the overall shape - especially as I don't have official drawings to work with.

No time for a full post tonight - I've been listening to Le Mans Testing all day since 8am, had some of the BTCC on TV this afternoon in the background, and now getting ready for the GP in twenty minutes! However, I'll have photos and developments updated tomorrow.

...and here it is.

First job for last week was to glue the wheel centres into the inner rims; once this was done I could start fitting several layers of 0.5mm strip to strengthen the join and to add some extra detail. When I'm ready I'll try running some of my liquid greenstuff into the grooves to smooth things out.

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby363_zpsac4d7af2.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby363_zpsac4d7af2.jpg.html)

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby364_zpsf6c12ec3.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby364_zpsf6c12ec3.jpg.html)

I then spent some time gluing the backing plates onto the disc bells - not totally straightforward as I had to match up each plate with the appropriate bell, and get the holes lined up correctly. Here's the two rears:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby365_zpscc53178a.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby365_zpscc53178a.jpg.html)

Another time-consuming job was to increase the thickness of the webs on the calipers. I'd felt for a while that they were a little on the thin side, so an extra layer of 0.5mm strip was glued in place and cut and filed to shape.

Whilst filing the side webs I also added a slight chamfer to the top and bottom edges of the caliper - this will provide a little extra space when the connecting pipework is added. You might notice that I've also added bosses for the fittings and glued the mounting flanges in position:

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby367_zps880eaf04.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby367_zps880eaf04.jpg.html)

Finally, the rear trailing arms have now had their reinforcing plates added on both sides of the hub carrier. I used 0.3mm sheet for these to make it easier to fit in place - it's not exactly structural. Sometime this week I'll add some greenstuff around the edges to finish it all off. The caliper mounts have also been fitted, so these can be 'welded' too.

http://i604.photobucket.com/albums/tt121/ScratchBuilt917/Scratchbuilt%20Porsche%20Moby%20Dick/moby368_zps72ffd453.jpg (http://s604.photobucket.com/user/ScratchBuilt917/media/Scratchbuilt%20Porsche%20Moby%20Dick/moby368_zps72ffd453.jpg.html)

That's it for tonight: up-to-date again. One thing I want to do this week is to finalise the front suspension geometry so I'm happy that nothing's going to foul. If I need to add thin spacers to the wheels, or tweak the measurements, I can. There's some greenstuffing to be done, and if I get really keen I can even start making some of the brake bleed screws, connections etc. We'll see...

SB