Build diary Porsche 356 Speedster Chesil replica - Final post May 17th 2021

End of the build process

The car is now fully and correctly registered as a Chesil Speedster 😀

Whilst I have thoroughly enjoyed all (nearly all) the build process, it has not been without some challenges. There was no accurate build manual which really didn't help, lots of undocumented issues that are "known" to the Chesil team but not documented and the wiring loom was to be polite, lacking! Most parts don't fit out the box, thank god for my Dremel and grinding wheels and I really underestimated how much research is needed to pull the build together.

The good news for future builders is that since I started Westfield has taken over of Chesil and I'm sure given time will sort out a decent level of documentation to support the amateur builder. 

A big thank you goes out to Goose at Chesil now Westfield who was a great source of information when needed.

An update on the carbs. The lesson is buy original Weber's not Chinese copies!!!

"Finished" Car

Build Photos

I have gathered together a few of my favourite pictures of the build process which I hope you enjoy.

Next Job

A bigger garage!!!

Update Feb 25th 2021

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Gearbox issue

It was really nice to drive the car out the garage, however on the test drive it seemed that I had a fault in the gearbox, 2nd gear would not engage when changing from 1st or 3rd. Pulling way in 2nd gear didn't sound "good". 

After several hours messing with the gear selector and gear selector rod unfortunately it seemed that it really was a fault in the gearbox. 

With the car so close to being finished not what I wanted!!!  Engine out time!!!!! 

Engine and gearbox out

Once the engine was out I did notice a small leak from the flywheel seal, a new seal has been fitted, sort of made me feel a bit better about having to take the engine out. It would have needed to come out at some point in order to fix the leak.

Oil from flywheel seal visible in the gearbox case.

The problem in the gearbox has been fixed,  it needed adjustment to the 1st/2nd gear layshaft and reverse gear.

Happy gearbox ready to refit

Engine & gearbox back in the car, quick test drive and 2nd gear now works 😅

IVA Prep

I have gone through my check list of all things relating to the IVA test. Below are a few photographs of the items where the edges need to be "softened".

If anyone wants my check list then let me know, it may not be complete but its a good start

Fixing tab on headlight needs covering

Interior rear view mirror requires rubber edge

Front indicator light requires rubber edge

Door mirror arms require rubber edge

Car overview ready for IVA

I think I have the car ready for IVA, fingers crossed. Booked in for first week of March, just need a dry day!!

Once through the IVA there is still a few jobs to do.

Steering will is for IVA only it will be replaced!

Trim Diary #2 - Dec 23rd 2020

Here are a few pictures showing the work completed since the last update.. Very close to being finished now.

🎅 Happy Christmas to everyone and lets hope for a better 2021!!🎅

🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄

Front bonnet complete carrying the same style from the interior

The sill and upright panel by the doors have been filled and sanded to achieve a perfect flat and straight edge, one issue with diamond stitch pattern is that you can see any unevenness in the panel being covered.

Centre tunnel looking good! 

Nearly finished! The seatbelt bracket is temporary only for the IVA test

Update Sept 3rd 2020

Rear parcel shelf

On a normal Chesil, the rear "seat" is a simple trimmed cushion. As I have mounted the oil cooler into the base of the rear shelf I needed to create a raised base to protect the cooling fan and also hide the audio amplifier. I drew up a quick sketch, then made a couple of rough prototypes then with the help of my local furniture builder they made the final cover. 

Sketch

Formed cover made from layers of bendable ply

Waxoyl

Thought I would inject some Waxoyl into the floor pan before the trim is started. Although this was done by Chesil as part of the floor pan shortening, looking at it I wasn't convinced. I have sprayed into the rear warm air inputs; interior heating ducts and anywhere else I could get the probe into!

Oil lines, refit tinware and engine bay seal

The external oil cooling circuit has proved to be a bit of a pain. Once I fitted the exhaust then I found the pipes were going be too close to the exhaust. I have had the pipes remade with different angle joints. I have also added a bracket to support the pipes and heat proof protection.

I have refitted the exhaust back box which I had to remove to sort out the oil hoses, 

Exterior trim

Fitted the lower side trim, had to send back one of the pieces as the quality wasn't good so waiting for a replacement. 

Fitted trim to front bumper, who knew how nice the car looks with no bumper fitted!!

Fuse and electric cover

I have made a cover for the electrics in the front of the car. It may or may not survive the final trim, but I think it looks ok. Made it out of shaped hardboard and covered it with a dark purple vinyl

Geometry

Lots of work here. Firstly setting up the ride height using the adjustable front beam and rear plates. A bit of a faff. Front end suspension setup for camber and steering geometry etc

Petrol tank

The petrol tank has now been fitted and connected.

Car rolled outside

Car out in the fresh air!

Next Jobs

• Test the engine for leaks then refit remaining engine tinware and engine bay seal
• I might adjust the rear suspension to give a little more ride height
• Final fix on sway bars front and rear
• A few small jobs
• Interior trim finalisation