1984 Porsche 928 S Bumper Grill Restoration

This 1984 Porsche 928 S has been in the shop for some repairs, service, and minor restorations. It was a gray market car, imported to the USA and originally sold in Germany.  Some modifications had been performed at different shops previously that was not to our customer’s liking.  One of the items we repaired in house was rebuilding the transmission and repairing the broken gauge cluster. Another item was trying to find a new old stock OEM exhaust to replace the awful sounding aftermarket exhaust – which to our amazement, we did. Another item on our customer’s wish list was to source a original lower center, 928 S bumper grill.

Sourcing the Grill

We were able to source a complete unit, in decent shape, which was not inexpensive even in this poor condition. We looked over the product listing photos and knew a thorough restoration was going to be necessary. This was definitely something we knew we could tackle in house. These photos below show the condition when the grill arrived.

When we received the grill we noticed all the hardware was rusty, so that would need to be refurbished or replaced. Also, the plastic brackets that hold the aluminum grill inserts were painted. They were also on the brink of breaking and extremely flexible. Those would also need to be replaced. Even though the brackets are still somewhat available on some specialty websites, we had an idea on how to upgrade these while still retaining the OEM look. Since we have multiple 3d printers in house, this technology was first thing that came to mind.

Disassembly

First, we started by disassembling everything and bagging and inventorying all the hardware. We took the metal grill inserts to our in house powder coating department to get stripped, blasted and coated.

Drafting the CAD Files

While the grill inserts were in powder, we took the brackets and scanned the profile them on a flatbed scanner. Since flatbed scanners, scan to a 1:1 ratio, we knew the profile sizing and dimensions on screen would be 100% perfect. We took the scans into Adobe photoshop and manipulated the contrast to make it easier to see the profile. After that, we saved the file and imported it into Adobe Illustrator. This is where we created vector outlines of the center and outside brackets. After the profiles were established, we deleted the imported scanned image and exported the file to a CAD format. We imported that into Fusion 360, where we drew up our 3d model for printing.

While in Fusion 360, we added additional supports, removed all the recesses that the OEM bracket have and pocketed each of the 5mm screw holes. Below is the transition of the files, from start to finish.

Flatbed Scans 1:1 Ratio
2d Vector Profiles Drafted
Final CAD Drawings Rendered
CAD Drawings Top

After the Fusion 360 CAD drawings were complete, we exported these to a .STL file and sent them to the 3d Printer. Our AnyCubic Kobra Max is capable of printing 15.9″ x 15.9″ x 17.7″ Tall. We can print a wide variety of materials such as PLA, TPU, and for more industrial applications, carbon fiber nylon blend.

Once the parts came off the printer, we mocked up the grill inserts to the brackets. To our amazement, the brackets fit really well, directly off the printer. Immediately we noticed how much stronger these were compared to the OEM brackets. Furthermore, the reinforcements allowed for very little flex to the upper grill section. We performed some minor finish work and deburred the pieces. When the grill sections came out of powder coating, they would be ready to assemble.

Assembly

At this point in the project, the grill inserts were out of powder coating and ready to go with a fresh coat of Cardinal Powder Semi-Gloss Black T002-BK08. We now started assembling the grill. However, one thing that was not compensated for while designing the brackets was the thicker tolerances.  When we reinforced the brackets joints in programming, we made them thicker than the OEM measurements. Our hardware was a little too short. We sourced some metric black oxide socket head screws that were 3mm longer.

Polycarbonate Carbon Fiber Grill Supports – Porsche 928

While installing the bumper grill, we found out a interesting thing. The North America (NA) bumpers grill brackets are different than the European E-Code bumpers. The brackets have a slightly different mounting location due to the fact that they are slightly shorter. To sold this, we had to modify the lower mount to be able to accept the NA brackets. It wasn’t worth printing new parts as we just had to drill a hole in each lower bracket and trim off the bottom tab just a little.

This is how it looked after installing the grill:

Porsche 928 Grill Supports
Porsche 928 Functional Application

In conclusion, the assembly went perfect after sourcing those. Overall the project turned out really nice.  We believe our customer will be really happy with the final outcome. Stay tuned for our next post where we remove and install the rear Porsche 928S decals and repair the gauge cluster using 3d printing technology again.

For more information on how to get your Porsche back to OEM condition, please call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from the former Boeing Store and on the westside of the Paccar / Kenworth plant.

 

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1960 Porsche 356b Shifter Rebuild

1960 Porsche 356b Shifter Rebuild

Last week our tech Jonathan and I were able to repair Craig’s (Rennfilms), 1960 Porsche 356b shifter. When driving this beautiful Porsche, It was difficult to find gears and made very sloppy shifts. This was due to the fact that it was missing the main lower ball pivot. It also had some poorly fabricated sheet metal, installed from the previous owner, which was not helping the situation. We had talked to Craig about this concern the last couple times he was in for service and seat bracket fabrication. We decided now was the time to do this.

Starting the project

First, I found a photo off the internet of the exact part we needed. This is really all we had to go by. Since we only had the shifter itself. The other measurements I had were the spring size and the dimensions for opening of the lower stick. I brought the photo into Adobe Illustrator and resized the photo so the hole size slightly larger that the known lower stick size of 20mm. Based off of that, I extrapolated the degree in which the photo was taken. After that, I calculated the outer ball perimeter, ball height and overall height. 

Next, I opened up Fusion 360 to start drafting our CAD file. Using our notes from the internet JPG image dimensions, I was able to come up with this drawing.

The 3d Printer

Since we print replacement parts with high temp resin, we must calculate the shrink rate. This is typically between 1-3%. Using a little simple math, that number needed to be around 103%. For safe measure, we printed 100% through 104%. Furthermore, there was going to be some margin of error. It takes about and hour to print these, so we wanted every option when we started assembling the shifter.. The 104% part fit best, although the 103% would have worked, we wanted some tolerance.

After the part came out we post processed it in a wash / cure station. Washing it with 99% isopropyl alcohol for 10 minutes and curing it with high intensity UV light for 6 minutes. This will harden the resin and prevent it from failing in the future.

While I was drafting and printing the parts, Jonathan media blasted the shifter housing and put a light coat of satin epoxy paint on it. We would have powder coated this in house, but the customer was picking up the same day. Powder coating will add a few hours to the project. If we need to make any adjustments in the future, we will powder coat it. Disassembly is fairly simple so it shouldn’t take too much addition time.

Assembly

After post processing the parts, Jonathan and I took them to the bench to test the sizes and fitment. You can see from this photo that the fit was spot on at 104%.

Parts all layed out
BottomPorsche Speedster Parts
Top fitment
Porsche 356 Speedster Parts
Close up of the assembly
Jonathan installing the shift linkage dry

From here, we performed a dry fit before lubricating the mechanism. They dry fit felt night and day better, and that was without any grease. We removed the shifter for the last time, greased up all the components and reinstalled the shifter assembly. The feel was 100% OEM and each gear was defined, with no lateral movement while in gear. Reverse felt so much different than before, which might take a little getting use to for the customer. (In a good way)

In Conclusion

Overall we were very pleased with how this shifter turned out. The customer was very pleased with the results. Considering the short wait time to make the part and its functionality, It’s pretty amazing that we can replicate parts like this. 15 years ago, this was mythology.

Since we have six different 3D printers (SDA resin and FDM filament), we have the ability to print polyurethane and other synthetic components. With build plate dimensions from 4-1/2″ x 2-1/2″ x 6″ tall all the way up to 16″ x 16″ x 17″ Tall – The possibilities are almost endless.

Information / Schedule

For more information on how to get your classic European vehicle or Porsche repaired, please call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from the former Boeing Store and on the westside of the Paccar / Kenworth plant.

 

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Project 1991 Mercedes-Benz 560sec

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Project 1991 Mercedes-Benz 560sec

It’s been a long road to completion but we finally got Project 1991 Mercedes-Benz 560sec finished today. Our customer came in about 6 months ago wanting to do a air suspension install on his 1991 Mercedes-Benz 560sec. We wrote him a quote based off his needs and some suggestions from Meister Werks. After approving the quote we ordered all the parts necessary to install his custom setup. The customer also wanted us to have the bumpers, side mouldings, mirrors and door handles painted white to match the body. We contacted our friends at Automotive Solutions to come out and do all the body work, prep and paint.

Fast forward a few weeks later, Covid-19 / Coronavirus hit the Seattle area and thus started the parts delays. It took a few months of waiting to get all the parts in. A few months later in March, we finally received everything and the install started very soon after. We also installed a kit on this customer’s 1990 Mercedes-Benz 500SL, which can be seen by clicking here.

The Install Begins

We began the install by removing the bumpers, side mouldings, mirrors and door handles. While these parts were out, we started polishing the OEM stainless steel trim. After all the parts went into paint, we began the air suspension portion. We started the air system by disassembling the custom stereo setup in the trunk. The car stereo installer had fabricated a custom enclosure to house the rose gold plated air tank, Air Zenith air compressors and Airlift 3p manifold. We bent custom hard lines, powder coated them white (to match the body) and affixed all the fittings to the components.

After we did this, we installed them into the custom build enclosure. Additionally, we wired the Air Zenith OB2 compressors with 4 gauge wires and 80 amp fuses. Futhermore, we ran the custom harness to the Airlift 3p manifold, then connected the remote wire to the ignition circuit. Once that was complete, we installed the 3p controller in the Mercedes-Benz 560sec center console.

Bend Lines
Mock Up
Mock up
Powder Coated Lines
Installed Hard Lines

 

Air Suspension Issues

We had many issues with the custom air bags we purchased from a company in Germany. The bags were rubbing on the body and the upper bag mount did not line up with the control arms. Countless hours corresponding, assembly, disassembly, reassembly, photos and diagrams were sent to the manufacturers. After weeks of communications, we finally got results and newly machined parts were shipped from Germany. After 3 additional weeks, we received new parts. Unfortunately the parts still did not work right. So we decided to machine the new parts in house to get them to work. What we machined was perfection and will be able to replicate this on any future projects. This Mercedes-Benz is now able to air up properly, lay frame and not rub on the body. These additional modifications to the air suspension were much better than the original kit.

 

More Custom

We also had to delete the Mercedes-Benz factory hydraulic suspension. To do this we removed the rear shocks, removed the hydraulic pump on the engine and machined a custom block off plate. We used 6061 T6 aluminum to machine this part in our inhouse machine shop. We also made a custom gasket on our CNC laser cutter. Everything installed perfect, with no leaks or issues.

 

Wrapping it up

With the components installed, we attached the air lines using OEM brake line clips to secure the air lines in place. While all this work was being done, we assembled and sealed the wheel. These were custom plasted rose gold on the AMG monoblock wheels. After sealing these three piece wheels, we mounted and balanced the tires. After test fitting the wheels, we knew we needed spacers on the front. To give this beautiful Mercedes-Benz 560sec a flush fit, we installed 20mm spacers all the way around.

After all of this hard work, we finally were able to test the system. We checked for air leaks, buttoned up the trunk, and make sure all the small details were ironed out.

Project 1991 Mercedes-Benz 560sec Build List

  • Airlift Performance 3p management
  • OB2 dual air compressors
  • 4 Gallon Specialty Suspension seamless air tank – plated rose gold*
  • Custom hard lines at Meister Werks
  • Air suspension install at Meister Werks
  • Front bags & hydraulic pump block off plate custom machined at Meister Werks
  •  Rose gold plated* AMG wheels & OZ lips & barrels assembled and sealed at Meister Werks
  • Bumpers, mirrors, door handles, moldings, body work & paint at Meister Werks by Automotive Solutions
    * All custom rose gold plating done at the customer’s shop in California.

To make an appointment for your custom air ride, stop by or call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from The Boeing Store and on the westside of the Paccar / Kenworth plant.

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Vintage Car Week at Meister Werks

This week is vintage car week at Meister Werks. We’ve had a number of vintage vehicles come in such as a ’64 Coupe Deville, ’64 – 13 Window VW Bus, ’71 Beetle and a 1977 Datsun 280z.

Coupe Deville is in for a air compressor refresh and wiring. 13 Window Bus came in for a plethora of service, repairs and upgrades. The Clementine Orange Beetle was dropped off for a crate engine install, all new upholstery, disk brake conversions, powder coating and many more custom items. Lastly, the ’77 280z came in for some repairs and some custom powder coating.

The Z and the Coupe Deville will be done next week, although the VW’s will be ongoing projects over the next month. Stay tuned for further progress reports on each vehicle.

 

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Powder Coated Brembo Calipers

Powder Coated Brembo Calipers

Last week, we Powder Coated Brembo Calipers for a customer. The customer purchased brand new calipers for his 2015 Lexus GS350. Since these were brand new in the box, there was little prep we had to do. We outgassed the machining oils by baking the calipers for a short time in our powder coating oven. After the calipers cooled off, we prepped them with solvent, masked off the critical areas and plugged all the threaded holes. To mask and plug the holes, we use a high temp silicone tape and plug that will withstand the temperature of our oven. The makes for an easy and trouble free installation for our customers.

After the prep is done, we powder coat the calipers, 2 coats of super durable wet red and 2 coats of clear coat. This will ensure the maximum amount of protection against road debris, discoloration and durability. As you can see, the finish turned out flawlessly.

Questions We Have Asked

Many people ask, “Why don’t you seperate the calipers (if they are 2 piece) or remove the pistons? The answer is many reasons:

  • First, you don’t want to separate the calipers. We’ve encountered customers who tried this and they will never seal again. This is because the caliper may slightly become disfigured from relieving stress and the torque to reassemble them. Also, the heat when baking does not help in this scenario.
  • Second, the pistons will heat up at the same rate of the caliper housing. This will protect against any media or powder getting into the brake cylinders. On used calipers, we have to media blast the brake dust off the calipers. We do not want to get meida inside the cylinder, which could affect braking performance.
  • Third, the dust seals. This will not affected by temperature change. Furthermore, the seals stay perfectly sealed and are make to take the temperature of high performance braking temperatures.
  • Lastly, Powder Coated Brembo Calipers is much easier for us as there is less to mask and prep.

Used Calipers

Before & After

We can coat used brake calipers, however the process requires more prep. We have to heavily outgas the caliper to get all the brake fluid out of the caliper. The powder coat will be destroyed if any brake fluid gets on it during the curing process. We also have to remove `100% of the old brake dust. Brake dust is non conductive and the powder will not stick to it. If the calipers are on the vehicle, we charge more to remove, prep, coat and reinstall them. They also need bleed so essentially, if they are already on the car, it’s sometimes better to paint them. You can see this process by clicking here.

For more information on how to get your brake calipers painted or powdercoated, please call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from The Boeing Store and on the westside of the Paccar / Kenworth plant.

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500+ HP Audi TTRS

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TTRS Performance Upgrades

The inline 5 may be the most stout engine ever produced by Audi. But for some, the best is simply not enough… A long time customer brought in his 2018 Audi TTRS for a Carbon Cold Air Intake, 4 inch Turbo Inlet, Wastegate Lines and to top it off with a Stage 1 tune all supplied by Unitronic.

 

UNITRONIC STAGE 1 FOR AUDI TTRS MK3 2.5TFSI EVO
• STOCK POWER: 400HP / 354LB-FT
• After Tune: 476HP / 469LB-FT

Unitronic Stage 1 Performance Software is for vehicles with 91 octane / 95 RON fuel, on a completely stock car. It is the performance upgrade that will result in the most gains! Performance Software for your ECU Box Code is subject to availability. 2019+ models may require to have the hood opened during the flashing process.

UNITRONIC STAGE 2 DSG FOR AUDI TTRS MK3 2.5TFSI EVO

Flashed directly through the (OBDII) Diagnostic port of your vehicle (10-15 minutes). Unitronic’s TCU Performance Software calibration enhances the gear shift speeds making them up to 70% quicker. D-mode (Drive) is for everyday daily driving and economy, while S-mode (Sport) is for faster acceleration. Unitronic’s TCU Performance Software unlocks the factory launch control limiter. The OEM launch control limiter blocks the engagement of launch control after only 200 launches.

Unitronic’s Stage 2 TCU Performance Software calibrations increase TCU torque limiters to allow for an increased output. It’s been developed alongside Unitronic’s upcoming Stage 2 ECU Performance Software for the ultimate overall experience. Unitronic’s Stage 2 TCU Performance Software calibrations increase clutch clamping pressure. It is perfect, alongside Unitronic’s Stage 2 ECU Performance Software. This supports an increase in engine torque output and ensuring that the clutches properly grip . This also will help for the higher output to be sustained. Includes all Stage 2 tune variants and all lower software stages as well.

For more info on these products, check out the Unitronic Website by clicking here.

To make an appointment for your TTRS, Audi or European car, please call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from The Boeing Store and on the westside of the Paccar / Kenworth plant.

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Powder Coated Production Run of Reinforced Clutch Forks

Powder Coated Production Run of Reinforced Clutch Forks

Today we powder coated a production run of reinforced clutch forks for Flipside Customs. These VW clutch forks are for 02A & 02J transmission and reinforced with the factory clutch fork in house at Flipside Customs in Renton, WA. These new OEM forks receive a TIG welded finish with water cut gussets. Factory forks are know to bend and go bad. Symptoms include increasing difficulty getting into gear, especially 1st gear. Really fast clicking or chattering sound in neutral with clutch completely let out. Sound may completely disappear if you press in the clutch.

If you are interested in getting powder coating quote for your production run of in house manufactured parts, contact us at 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from The Boeing Store and on the westside of the Paccar / Kenworth plant.

About Flipside Customs

Flipside Customs owner, Rob Hancock, specializes in custom design, fabrication and welding services.  Customers can expect an increase in functionality, performance and overall quality with his 20 years of experience.  Rob started his career working on street rods; a passion passed down through the generations.  While continuing to work on street rods, he branched out to production based welding on speed related products. He also gained experience in the machining industry which yet again expanded Flipside’s diversity.  Rob has continued to use his skill set to benefit his customers in ways that separate his work from others.

Also, questions like; “Is this possible?” will be quickly answered with “let me show you how!”. As an avid racer himself, he saw and experienced several areas to improve on during his time on the track.  He began designing, modifying and fabricating custom race components that have increased both performance and functionality both on and off the track. As a lover of both two and four-wheel vehicles, Rob has expanded the business to include custom motorcycles, street, and race cars as well as off-road vehicles.  If you are interested in what Flipside Customs has to offer, please contact Rob at Rob@flipsidecustoms.com.

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Custom Wheel Refinishing

Custom Wheel Refinishing

A customer of our came in for wheel refinishing with his Jeep SRT. He wanted to change the color from the polished aluminum to gloss black. We removed the wheels from his Jeep and put it on jack stands during the wheel refinishing process. Then we removed the tires. We noticed all the the wheels had some curb rash damage. The customer opted to repair all the rash which was a little extra in labor cost. We began the wheel refinishing by stripped this wheels in a chemical bath. This removes all the paint, clearcoat and any dirt or debris. It also etches the surface slightly. After stripping we repaired the wheel damage and media blasted the surface to insure powder coat adhesion to outlast the warranty we provide.

After the wheels were cool and came out of the oven, we hand painted the inside of the SRT logo with silver leaf paint. After all was said and done, the wheels turned out well.

To make an appointment for your wheel refinishing, please call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from The Boeing Store and on the westside of the Paccar / Kenworth plant.

After Stripping
Wheel Damage
Curb Rash
More Wheel Damage
Finished
SRT Logo
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2002 Dinan E46 M3 Service

Today we performed a oil change service and alignment on a 2002 BMW E46 M3 with a Dinan sport package.

The customer requested a specific oil. In this case, it was Redline 10w60 race oil. While performing the service we also completed our 30pt courtesy inspection. We found a few items that need addressing. Oil leaks on and around the Votex V-2 super charger and power steering reservoir leaks.

Luckily we caught these issues and will be able to schedule another appointment to get these items repaired.

This Dinan S3R E46 M3 boasts an impressive 462 Horsepower @ 8000 rpm & 328 lb-ft Torque @ 6000 rpm. This has a software upgrade, FMIC, Votex V-2 Supercharger, upgraded throttle bodies, performance camshafts, free flow exhaust, limited slip differential, tie bars and sway bars. It also has a Koni suspension system that will hug the curves and keep all this raw horse power on the road.

To make an appointment for your BMW, European or Import, please call 425-254-0627. You can also schedule an appointment online by clicking the link below. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from The Boeing Store and on the westside of the Paccar / Kenworth plant.

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Tracy’s Project 2018 New Beetle Coast – Part 1

Tracy’s Project VW New Beetle Coast – Part 1

Tracy’s stock VW New Beetle before we started her project

Our long time customer Tracy brought her 2018 VW New Beetle into the shop a few weeks after she purchased it from Auburn VW. Our good friends at Auburn VW had recommended Meister Werks to her after she ask where to take it for some modifications.

Tracy had a laundry list of items she wanted for her VW New Beetle when she came in for her consultation. Some of the items were winter wheels for her snow tires, lowering the vehicle, summer wheels / tires and some performance mods, just to name a few.

Starting the Project

VW New Beetle “Winter Mode”

The first item she opted for was the lowering the car. She wanted simple lowering springs. We advised her that running OEM shocks and struts with lowering spring would eventually damage the shocks and struts. Since those parts are not meant for lowing spring, they wouldn’t last that long and would decrease the performance over time.

We suggest the K-Sport adjustable coilovers which will allow her to adjust the VW New Beetle to any height she will like. This kit would also increase performance without sacrificing the quality of the ride. They are also adjustable dampening, which will allow her to change the suspension to softer or stiffer ride. The cost difference was not much more and she opted to go that route. We also found her some inexpensive satin black Platinum 432SB Elite wheels. We mounted and balanced the tires for her and installed them after the suspension was installed.

Lowered on Radi8 R8S5 Wheels

When spring rolled around, she started looking for her summer wheels and tires. We layed out all the catalogues and option for her. She wanted something unique that not a lot of people have. As soon as she saw the Radi8 R8S5 wheels, she knew that is what she wanted. The look and feel of Tracy’s beetle is one of a kind.

Radi8 R8S5 Wheels

Future Plans

Some future plans are to install a 3″ down pipe, Stage 2 Unitronic performance tune, DSG Transmission tune and cold air intake. These modification will give this VW New Beetle around 300hp. So if you see her at a stop light, don’t underestimate what this Beetle will be able to do.

Tracy is a regular at Meister Werks and if you see her in the lot or our lobby, feel free to ask her any question about her car. She loves to meet new people and is a genuine awesome person.

If you are looking to modify your vehicle, contact us at 425-254-0627 or come in for your free consultation. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from The Boeing Store and on the westside of the Paccar / Kenworth plant.

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