Customizing Your Porsche 914-6/GT Engine Lid

Customizing Your Porsche 914-6/GT Engine Lid: A Step-by-Step Guide

In building a GT replica, we aim for a meticulous match in design for the engine lid. Unlike typical designs, we ensured the two screens would seamlessly align down the middle. Here's how this project diverges from conventional methods. We retained the excess metal at the lid's rear, ensuring it remains uncovered by an additional original grill.

Tools and Materials Needed:

• Extra 914 grill
• Cut-off wheel
• Tin snips
• Sabre saw with metal blade
• Die grinder
• Vise
• Drill
• Body hammer
• Dollie
• Flanging pliers (optional)

Step 1: Preparing the Grill

To kickstart your Porsche 914-6/GT engine lid project, use an extra 914 grill in the opposite direction. Start by removing the mounting tabs from the long side where the two grills will meet. This step ensures the original tabs can align properly in their designated holes without obstruction. Use a cut-off wheel to cleanly remove these tabs.

 

Step 2: Bending and Shaping

After cutting out the tabs, focus on shaping the grill to fit the lid precisely. The grill should sit flush with the front edge but may stand off slightly in the middle. Flatten the grill's ends and straighten any bends using a vise and body hammer. This process ensures a uniform fit along the lid's surface.

 

Step 3: Test Fit and Marking

Place the grill on the lid to verify the fit. Use a scribe to mark the locations of remaining stock mounting tabs. Once marked, drill corresponding holes on the lid for secure attachment.

Step 4: Modification of Lid Components

Proceed by drilling out spot welds on the cross brace and trimming the center spring mount as needed. Precision in these modifications ensures proper alignment and functionality without compromising structural integrity.

Step 5: Creating the Template

Utilize the front section of the lid with its existing mounting surface as a template. Cover this section with masking tape and trace the outline using a pencil. Transfer this template to the rear section of the lid, ensuring alignment using the center hole as a guide.

Step 6: Completing the Template

Extend the masking tape and draft the new opening on the back half of the lid. Use measurements similar to those of the front half to maintain a consistent appearance.

Step 7: Cutting and Final Adjustments

Prepare to cut along the traced lines. Begin by drilling starter holes and use a sabre saw for the main cuts. Exercise caution around mounting braces and use a cut-off wheel for precise trimming. Be meticulous near the front of the lid where the sheet metal rests closely on the brace.

 

Step 8: Bending the Back Lip and Modifications

Next, the focus shifts to bending down the back lip of the lid. This step requires finding suitable tools like flanging pliers or other recommended alternatives from knowledgeable members of the 914club. Bending the lip ensures a smooth and finished appearance along the rear edge of the lid.

Once the lip is properly bent, proceed with trial-fitting the grill onto the lid. Evaluate the fit carefully and make any necessary adjustments. This may involve slight cutting and modifying the grill around areas where it meets the bent lip for a precise fit.

Additionally, retain the rubber beading that came with the grill to enhance the aesthetic and ensure a clean finish along the back edge of the lid. The beading serves to tidy up the junction between the lid and the grill, contributing to the overall polished look of your custom Porsche 914-6/GT engine lid.

Step 9: Initial Assembly and Adjustment

After completing the previous steps, proceed with fitting the original grill back onto the lid along with the modified grill. Test-fit both grills together to ensure they align seamlessly and complement each other visually.

Additionally, use a MAP torch (highly recommended tool) to adjust the springs. Hold each spring securely in a vise and carefully bend the end inward about halfway from its original position. This adjustment aims to replicate the lighter tension of the 914-6 springs, optimizing the functionality of your engine lid without the need to source a new pair.

Step 10: Bending, Trimming, and Preparing for Finishing

To complete the assembly of your custom Porsche 914-6/GT engine lid, follow these final steps:

1. Use Vise-Grip Sheet Metal Bending Pliers: Employ a pair of Vise-Grip sheet metal bending pliers along with a dollie and body hammer to perform the final bend of the back lip. Ensure the bend is uniform and aligns smoothly with the rest of the lid's edge.

2. Trimming the Rubber Trim: Trim the extra piece of rubber trim to fit precisely along the back edge of the lid. This step ensures a clean and polished appearance where the lid meets the grill assembly.

3. Preparation for Sandblasting: Remove the entire lid and grill assembly to a sandblasting facility. This process will effectively clean all surfaces, removing any rust, paint, or contaminants to prepare the metal for primer and paint.

Step 11: Adjustments and Preparation for Finishing Touches

After retrieving the lid and grill assembly from the sandblaster, proceed with the following steps to complete your Porsche 914-6/GT engine lid project:

1. Rear Bend: Ensure the rear bend of the lid is fully completed and aligned to your satisfaction. Test-fit both grills once again to verify they fit seamlessly after sandblasting. Additionally, check the springs to ensure they are correctly positioned and functioning as intended.

2. Applying Filler and Finishing Edge: Disassemble the lid and apply a small amount of filler to the edge that was bent down and hammered with the body hammer. This step smoothens out any imperfections and prepares the surface for painting. Allow the filler to dry completely.

3. Priming and Painting Preparation: Tomorrow, finish off any remaining tasks on the lid assembly. Prime both the grills and the lid itself to protect the metal and provide a suitable base for paint adhesion. If weather permits, consider applying a finish coat of paint for a complete and professional look.

Here's the parts hanging in the sun...