[WIP] Porsche 924 Safari electric

[mrfred]

Time to share my project. I will be converting a 1979 Porsche 924.

The goal of the project besides completing the conversion is to learn how to weld, restore and have fun along the way. The car was in very poor condition when I bought it and I have no experience with welding or fabrication. So it's taking time but slowly, slowly, progress is being made.

A large part of the project involves rust repair and I will be more or less restore everything on the car including a completely new 12V system.

-- Plan --
Car: Porsche 924, raised and with offroad tires. Yes I know! Bad combination for an EV
Powertrain: Mitsubishi Outlander rear drive unit and inverter.
Charger: MG ZS EV(?) 3-phase charger
Battery: 35kWh VW e-Golf battery

[mrfred]

Repaint in white 2k bedliner.

[tom91]

Mitsubishi Outlander rear drive unit and inverter.

What sort of performance are you expecting? This is quite a limited power drive unit which will have lower performance then the stock vehicle most likely.

[mrfred]

Dashboard restoration.

[mrfred]

What sort of performance are you expecting? This is quite a limited power drive unit which will have lower performance then the stock vehicle most likely.

Not very high expectations. Over time, it could become a more exciting drive train but for now this is more of a learning project

[mrfred]

As I said, the goal is to learn. I will do all the welding with TIG but a friend was nice enough to step in and weld the motor mounts. I dont trust myself just yet to do the important welds..

[Bratitude]

nice work on making drive shaft flanges instead of custom axles!

[mrfred]

nice work on making drive shaft flanges instead of custom axles!

Thanx!

[mrfred]

Engine bay and cross member touch up:

Steering rack refurbish:

iBooster, Wilwood proportioning valve and bracket install and creation:

[mrfred]

Trying out zinc plating. I'm not sure if I think the style suits the car, but it's fun to experiment!

[crasbe]

The results look really nice and I don't want to be that guy, but be careful when zinc plating bolts (or parts in general). They can lose a lot of their original strength due to hydrogen embrittlement.

[mrfred]

The results look really nice and I don't want to be that guy, but be careful when zinc plating bolts (or parts in general). They can lose a lot of their original strength due to hydrogen embrittlement.

Didnt know that. Thanx for telling me!

[jrbe]

Looks good.

You can do a post plating bake soon after to combat the hydrogen entitlement. Look up specs for what you're plating.

[DVD3500]

Warning: Slightly off topic

The results look really nice and I don't want to be that guy, but be careful when zinc plating bolts (or parts in general). They can lose a lot of their original strength due to hydrogen embrittlement.

Which is one of the reasons pumping hydrogen into natural gas lines is a huge risk as well... Furnaces are being sold as "hydrogen ready" which is the same as saying my garage is "Ferrari ready". When pipes start cracking and hydrogen starts leaking all over people will see what an idiotic use this was for hydrogen...
Rant over.