Building a 904

Share progress on your 356 related project or full restoration with others!
Message
Author
User avatar
Adam Wright
Classifieds Monitor
Posts: 10321
Joined: Wed Mar 12, 2008 1:00 am
Tag: KTF

Re: Building a 904

#61 Post by Adam Wright »

Bill Sargent wrote: Tue Oct 31, 2023 8:04 pm This project is definitely not about instant gratification! I placed my order in August 2015, construction was started in September 2018 and I am at least a year out from the car shipping to the US after which at least another 6 months if assembly will be required. However the longer it takes the more parts I am able to make.
My two projects are 7 years deep, but I tell myself life is about the journey, not the destination.
www.unobtanium-inc.com
Check out my Barn Find column in the Registry magazine, always looking for good stories.

User avatar
Bill Sargent
356 Fan
Posts: 1147
Joined: Thu Apr 10, 2008 11:03 am
Tag: Faux-Cam
Location: Seattle, Washington

Re: Building a 904

#62 Post by Bill Sargent »

I got the 904 jack restored and also found a correct length ratchet on eBay for $60 from a guy in Serbia!
904 Jack and Ratchet.jpeg
I also spoke with Barrie Martin, the constructor, last week and he has the car booked into the paint shop on 1 March. He should have it back 2 to 3 weeks after that. I plan to visit him in the UK for 2 weeks in April to help with several tasks. We plan to test fit the suspension using the 3D printed plastic suspension bolts, install the windscreen (heated and US DOT approved), install the seats, install the dash top and wiper motor mount and many other small things.

We agreed that I will purchase a 20 ft container for delivery to his shop in early August. The car will then ship in early September. The suspension will ship in a separate crate at the same time, so the car will be on a rolling dolly in the container. Anything that is not complete at that time I can do here in the US. To enter the US as "car parts" with duty at 3% the car can't have the suspension or drivetrain with it. The drive train is no problem - it is sitting in my shop. But the suspension has to be shipped separately.

With any luck I will be assembling the car in my shop over the 2024/25 winter and hopefully driving it in the summer of 2025!
Regards,

Bill Sargent
#151489 59A Cab - Faux Cam
#159176 64C Cab
#460603 67 912
904 clone in the works

Puygranier Antoine
356 Fan
Posts: 85
Joined: Wed Jun 03, 2020 3:19 pm
Location: Stuttgart-Germany

Re: Building a 904

#63 Post by Puygranier Antoine »

Great work on the jack..and sounds like a great plan for the car, can't imagine how excited you are to see it coming together!

Antoine

User avatar
Bill Sargent
356 Fan
Posts: 1147
Joined: Thu Apr 10, 2008 11:03 am
Tag: Faux-Cam
Location: Seattle, Washington

Re: Building a 904

#64 Post by Bill Sargent »

As usual with projects things do not go as quickly as planned. The paint shop is behind and paint completion is now estimated to be late April.

Before going to the paint shop all movable panels were fitted and the 3D printed plastic prototype rear clamshell latches were tested.
Pre paint 1
Pre paint 1
Pre paint 2
Pre paint 2
Rear clamshell latch handle
Rear clamshell latch handle
Rear clamshell latch pin
Rear clamshell latch pin
The latch shown above was a prototype without the spring mechanism. I now have a working prototype with the spring mechanism.

The car is now being prepped for silver paint however before the silver goes on the roll cage gets primed and painted black.
Paint shop 1
Paint shop 1
Paint shop 2
Paint shop 2
Paint shop 3
Paint shop 3
In parallel with the paint shop work the gas and oil tanks are also being fabricated.
Gas tank 2
Gas tank 2
Gas tank 2
Gas tank 2
I hope to make a trip to the UK in early June to test fit the suspension and other parts.

Thanks for following along.
Regards,

Bill Sargent
#151489 59A Cab - Faux Cam
#159176 64C Cab
#460603 67 912
904 clone in the works

User avatar
Martin Benade
356 Fan
Posts: 12388
Joined: Wed Nov 23, 2011 10:52 am
Location: Cleveland, Ohio

Re: Building a 904

#65 Post by Martin Benade »

Bill, that’s all looking outstanding. I hope you don’t mind if I’m insanely jealous. Regardless. I am!
Cleveland Ohio
62 Cabriolet
56 VW
02 IS 300
04 Sienna

Richard Emerson
356 Fan
Posts: 775
Joined: Wed Jan 29, 2014 1:43 am

Re: Building a 904

#66 Post by Richard Emerson »

Bil Brown wrote: Mon Mar 06, 2023 4:27 pm I have a couple of original 904 alloy/steel wheels.....if anyone is looking.
And I have three 904 alloy bimetal wheels (3.7mm thickness) that are available as well.

Lawrence Wach
356 Fan
Posts: 48
Joined: Sun Jul 30, 2023 8:48 am
Location: CA

Re: Building a 904

#67 Post by Lawrence Wach »

Wow, Bill, you mentioned this project when you were at my shop a while back, (your cab was here for repair at Trevor’s, and I stored it overnight for you), I had no idea you were in this deep. You are a busy man!

Major kudos!

I will now follow along (in amazement) and hope to see the car in the future. All the best to you!

User avatar
Bill Sargent
356 Fan
Posts: 1147
Joined: Thu Apr 10, 2008 11:03 am
Tag: Faux-Cam
Location: Seattle, Washington

Re: Building a 904

#68 Post by Bill Sargent »

Hi Lawrence - yes, I am in about as deep as one can get without spending north of $2 million for a factory car. I hope to go to the UK in June for a couple of weeks to test install the suspension and install other parts.

Spent some time today doing CAD work to get the rear vented rotor brake caliper carrier into CAD. I have been using Autodesk Inventor for about 14 years now and a part like this can be made in about an hour.
904 Vented Rotor Rear Caliper Carrier.jpg
Regards,

Bill Sargent
#151489 59A Cab - Faux Cam
#159176 64C Cab
#460603 67 912
904 clone in the works

Post Reply