[h2pmr]

in the early fabrication stage
headlight pod, fuel rail, cam sprocket, cam sprocket washer and possible crank damper pulley.
well it seemed like a good idea after a few .....
cheers
Phil

[h2pmr]

more progress and i think its all going to work.
the end tube part of the fuel rail in the above post i have managed to cut good threads into = size M11 x 1.5, not many nuts that size but managed to find one, as below.
just need to make a sleeve to center it in the cam sprocket, then tighten nut and that will hold it to the cam sprocket


then using the original 3 adjuster bolts that hold the cam sprocket, drill and tap the damper and bolt all together



lots of lubrication later i can get the wire all the way down through the fuel rail and out the bottom, then just need to drill a hole in the cam sprocket teeth to let the wire out.
also need to machine the center of the damper so it sits flat on a table, looking at the middle picture above there is a 2mm gap between table and damper

should look better when its all painted, might mention it on a UK forum and see if anybody wants it painted in their cars colour, give the painter in our body shop something different to paint.

cheers
Phil

[h2pmr]

pretty much all built, still needs correct Porsche bolts, washers etc, as its just at full mock up stage.
wire will be going down through the fuel rail and out through the damper when its all painted
tried to use the 3 adjuster bolt holes but to close to the center of the damper so could not get a flat surface to tap a hole into so had to use the larger outer holes
looks good to me, better when its all painted.
any takers this side of the pond for a useable one off piece of 928 artwork?

[h2pmr]

now fully built and painted, got the main painter in our body shop to mix the paint to the paint code of my SE and his apprentice to paint the headlight pod inside and out
as from the above posts the only thing Porsche i could find to center the fuel rail in the sprocket with was a drilled out wheel nut covered with heatshrink to make it a good tight fit:




then drill an outlet hole in the cam sprocket and damper to feed the wire out through



getting the wire down through the fuel rail the hardest part, had to feed a thin wire down first then solder that to the mains wire and pull it through.
then fit the bulb holder and switch to the freshly painted headlight pod, a careful masking of it and the wire and i sprayed the rest of it with brake caliper silver.
then fully assemble, black felt stuck to the bottom of it to stop desk being scratched and the first one is done.
cheers
Phil

[h2pmr]

the finished article

cheers
Phil

[h2pmr]

thanks for the idea Carlos
saves me ffing about getting the wire down the inside of the fuel rail
cheers
Phil

[h2pmr]

20231116_201650.jpg

[worf]

Those are awesome Phil!