Machining and Fabrication Work
Below are some examples of tool and component fabrication we've done for ourselves and our clients.
Carrera GT Lift Plates
BMW Alpina B6 3.5 Radiator Repair
The early original Alpina B6 3.5's were assembled with Langerer and Reich aluminum radiators with cast tanks. In the distant past this particular car suffered a blown head gasket that overheated the engine and blew out the radiator. At that time, a technician repaired the radiator using an undersized brass neck and brazed it in at the wrong angle, leaving a spliced hose the only visible sign of an ugly repair. Our solution was to source the original hose from Alpina and modify the radiator to allow the intended fitment and aesthetics to reign supreme.
Ferrari 288 GTO A-Pillar Plates
During the course of a major service on this GTO, we decided to fabricate new plates to cover the door hinges to replace the existing damaged ones. We were happy with the results!
Carrera RS 3.0 Engine Oil Bypass
Upon inspection of the engine case of a Carrera RS 3.0 while rebuilding the engine, we noted that the oil bypass hadn't been performed. The owner desired to update the lubrication system by having this done so we set the case up in the mill and performed the modification.
512 BBLM Hood Pins
During the restoration on a 512 BBLM we fabricated some new hood pins to replace the old, haggard ones.
Porsche 911 Fan/Hub Restoration
The signature of the 911 Mezger engine is it's cooling fan. If the fan looks right, the engine looks right. Period. Over time, these fans accumulate dirt, debris, chips, pits and the cad or zinc plating on them tarnishes, revealing a corrosion that isn't easy to hide. I developed this tool and special ordered new rivets to allow separation and convergence of cooling fans and their hubs when deemed appropriate....which is pretty much always:)
Ferrari F40 Suspension Risers
A client had mentioned that his F40 seemed to ride lower in the front than in the rear...or so it seemed. He desired a more level look and requested that I look into it. After a fair amount of inspection, measurements, research and consultation with some Factory Ferrari guys, we decided to raise the front of the car by preloading the front springs. I made some shims to incrementally raise the front of the vehicle until the desired height was reached. When we had our spacer dimension nailed down, I fabricated a pair of spring perches and the augmentation was completed.
1958 Porsche 356 Speedster
A 1958 356 Speedster needed an new engine. An earlier model engine was selected and assembly began. In order to satisfy aesthetic requirements and install the period correct oil manifold and hoses, a special fitting was needed to make the connection possible. I fabricated this fitting, modeling it after a factory part, and sent it to our cad platers with the rest of the hardware so that it looked factory clean like it belonged.
911 Strut Towers
This doesn't really belong on the fab page but we decided to mix it up a bit. When the early 911 cars were built, the factory applied a thick, tar-like substance to the front upper shock tower that covered the shock mounts. Over time, this thick goo turned rock hard and will prevent camber and caster adjustment if left in place. On Jim's '81, we removed the tar and performed a track suspension setup(alignment) so he could get the most out of his cornering ability.
Dino 206 Brass Bushing
The Dino 206 has a brass bushing(threaded adapter) in the front cylinder head that houses the oil temperature sending unit. When we built the engine we discovered a crack in the bushing. Since these cannot be bought, we fabricated one on our lathe.
Dino 206 SP Harness Bungs
The Dino 206SP is the competition version of the Dino street car. We were tasked with finding a way to attach modern racing harnesses to the chassis without modifying the structure of the car. We decided to fabricate straps to go around the tubing in order to attach our outboard lap belt mounts. This is what we came up with:
GT3 | GT4 Carbon Fiber Sport Seat (LWBS) Modification for Sub Strap
Our client wanted to install 6-point harnesses in his Cayman GT4 so we did what we always do....a clean install. The passenger seat is not built with a sub-strap pass-through so we created one, matching the factory pass-through in the driver seat. This was no easy task but we were successful in modifying the upholstery as well. This satisfied both function and aesthetics. Peep it-
Audi RS4 Brake Duct
We had a client that tracked his RS4 and complained that, often, he would overheat his brake rotors. Without intrusively modifying the car, we came up with a solution to add cooler ducts to his front brake system to help reduce the temperature. We discarded his OE rotor backing plate and replaced it with one from a different model that incorporated a cooling scoop. Noticing that the steering knuckle interfered, we cut a hole and covered it with rubber to allow free movement of all parts without interference.
Lamborghini Intake Pressure Test Bungs
To properly set up the CIS Injection System and the engine's idle speed on a 25th Anniversary Countach, it is necessary to measure and balance the pressure inside the intake manifolds. Doing this requires a special bung not available in the retail market. We fabricated these bungs from hex stock to quickly and accurately measure manifold pressure.
Ferrari 275 GTB Weber DCZ Choke Bushings
During the restoration of a 1966 Ferrari 275GTB, we were going to through the carburetors and noticed that the bushings that helped operate the choke were missing. All of our Weber parts sources told us that these were unavailable so we made some on our lathe from 1144 Carbon Steel.
Ferrari 288GTO Clutch Master Cylinder
The original Ferrari 288GTO clutch master cylinder is secured to the firewall via 2 8mm studs. This cylinder, being prone to leakage and failure, is best to replace with a german unit. The replacement cylinder, however, has a different mounting flange. We modify the master cylinder mounting flange by facing the backside and drilling the threads out so that it will easily fit it's new home.