1960 Porsche 356b Shifter Rebuild

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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
Bottom Fitment
Top fitment
Assembled
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.

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 install them into the custom build enclosure. After that, we wired the Air Zenith OB2 compressors with 4 gauge wires and 80 amp fuses. We also ran the harness to the Airlift 3p manifold, connected the remote wire to the ignition on circuit and installed the 3p controller in the Mercedes-Benz 560sec center console. 

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. The Mercedes-Benz is now able to air up properly, lay frame and not rub on the body. These additional modifications to the air suspension was 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 cutter. Everything installed perfect, with no leaks or issues.

The components now installed, we attach the air lines using OEM brake line clips to secure the air lines in place. While all the the work was being done, we assembled and sealed the custom rose gold plated AMG wheels and 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 when rolling down the road.

After all this hard work, we finally were able to test the system for air leaks, button up the trunk and make sure all the small details were handled.

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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Code, Update & Program Control Modules

Coding, Updating & Programming Control Modules

Meister Werks now has the ability to code, update & program control modules. We can fully scan your BMW, VW or Audi and verify that the control modules are up to date.

The manufacturers regularly update software that is necessary for a efficiently running vehicle. When cars are first manufactured, the parameters are written for very tight tolerances. As the cars age and parts start to break in, some parameters can slightly shift out. This can cause check engine lights or components to no longer function. Often, this does not mean than the part is faulty, the software just needs updated. Just like your laptop computer or smart phone.

2006 BMW M6 V10

In the case of this 2006 BMW M6 V10, there were many modules that would not function even after we replaced the faulty components. The communication between modules would no longer talk to each other. After scanning this BMW with our new software, we found many modules were out of date. After performing an update, the car ran and sounded much better. The steering column switch that failed, now is functional. The software will also tell us if there is a faulty component, a wire short and where the location of that is. This makes diagnosing you vehicle much quicker and the result is a potentially smaller repair bill.

In this instance, the screen shot shows the version ID from BMW’s plant in Munich, Germany (outlined in red) is much older than the software on the vehicle. Our software connects directly to the manufacturer, insuring the most up to date software is loaded onto your vehicle. This will update everything from engine control modules and transmission control modules to the radio, battery control modules and even the instrument cluster.

More Info

If you have any questions about this service, feel free to contact us any time for a estimate or an appointment. To make an appointment for your vehicle’s coding, updating & programming control modules, call 425-254-0627 or email us. 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 west side of the Paccar / Kenworth plant.

 

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Porsche 911 / 996 Headlight Refurbishing

Porsche 911 / 996 Headlight Refurbishing

Our customer brought in his set of Porsche 911 / 996 Turbo for headlight refurbishing. The lens were oxidized and dull when they arrived. This is cause from the sun light’s UV breaking down the surface of the lens. We wet sand all the contaminants out, clean and spray with our special clearcoat. This clearcoat is the same acrylic makeup as the lens which bonds with it down to the molecular structure. Not only that, but the clear coat adds a layer of protection against fading or oxidation. The clear coat also dries very glossy and there is no need for wet sanding or buffing after the clear coat dries. However, we can do this and is an additional option if you upon request.

Note: Some imperfections are within the inside of the lens area and are unable to be removed. New housing would be an alternative to getting brand new headlights.

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Audi S4 3.0t PCV Coolant Leak w/ Carbon Cleaning

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BMW Wheel Alignment

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Dustless Sandblasting

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Powder Coating Harley-Davidson Parts

Powder Coating Harley-Davidson Parts

Our long time friend Pete came in last week for powder coating Harley-Davidson chrome parts for his motorcycle bike. Since we can not powder coat directly over chrome, we knew we had a challenge.

We would need to etch the chrome in some way for the powder to stick. We ended up media blasting the chrome with 34 grit aluminum oxide. This takes about four times longer than any other material to etch.

We set up our automated media blaster with rotisserie to blast his items for about an hour. After that done, we did touch ups for around 30 minutes to get everything even and etched properly. We then cleaned and prepped the surface throughly and hung the parts for powder coating. We use Cardnal Industrial Finishes, BLACK Super Durable 90 Gloss, color code P009-BK180. This extremely glossy powder will withstands the riggers of the road and lasts five times longer than any other powder. As you can see the finish and the glossiness is pretty amazing.

To make an appointment to have us do powder coating Harley-Davidson parts, call 425-254-0627 – Ex 0, or email us. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA.

 

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Mounting and Balancing Tires on Flat Lip 3 Piece Wheels

Mounting and Balancing Tires on Flat Lip 3 Piece Wheels

We regularly receive jobs in the shop for mounting and balancing tires for flat lip, 3 piece wheels. This can pose a challenge as the back barrels do not have a drop for us to dismount the tire properly.

When performing this service, we have to remove the face side tire first. We always use the Motion Pro Rim Shield guards to protect the wheel lips. After that, we remove the tire from the machine. Using the bead breaker, we push the rest of the tire off into the tire well or tire drop portion of the wheel. Once this is achieved, we return the wheel and tire to the machine and remove the rest of the tire. Mounting can also be challenging, but in this video instance, there was not a problem. People with stretched tires will have more issues getting them to bead on the wheel lip beads correctly.

Even though this video is sped up, this requires more labor to remove the tire. We charge an hourly rate for all custom 3 piece wheels. If you have a standard wheel, made by your vehicle’s manufacturer, there is no need to worry. There will not be any additional charge for standard wheels.

With a purchase of tires at Meister Werks, we also offer free flat repair, free tire rotation and we will warranty your tires if there is a warranty issue with the manufacturers milage warranty. Anther service we offer is wheel alignment. On our state of the art 3d laser alignment machine, we will be able to dial in your alignment. This will eliminate unnecessary tire wear and prolong the life of your tires.

To make an appointment to have your tires changed, call 425-254-0627 or email us. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA.

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How to Prep Parts for Powder Coating Correctly

How to Prep Parts for Powder Coating Correctly

Left part after chemical stripping, right after chemical stripping and media blasting. This is how the left part should have looked and why the powder flaked off.

This weekend, our good customer Keith dropped off a few items he needed powder coating correctly applied for his 2014 Subaru Impreza show car.

The bumper canards Keith purchased from an aftermarket parts company coated them satin black. As he was installing the parts onto his car, the powder started flaking off around the screw holes. Immediately he knew that he needed to get them recoated and have them powder coated correctly.  Keith called us on Thursday and we told him we would need to strip them back to bare metal and correctly prep them for powder coating correctly.

Keith’s 2014 Subaru Impreza Before Installing Parts

We chemically stripped them and after 5 minutes, we knew they were not prepped the right way. As you can see in the photo, the part on the left is how the company coated the part. The part on the right is what the left should have looked like and taken about 30 minutes to chemical strip. The part on the right was media blasted at Meister Werks with 36 grit aluminum oxide. This will give the powder ‘bite’ and allow it to stick much better than the smooth surface seen on the left part. This exactly why you can not powder coat over chrome. There is nothing for the powder to stick to and will flake off almost immediately.

The next time you need your project done correctly, call Meister Werks. We do large production runs and single items as well. We also shoot satin black almost every Friday as a part of our Black Friday special. To make an appointment or with any questions, call 425-254-0627 or email us. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA.

After Powder Coating

After Installation

After Installation

 

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