R7 Throttle Pedal Extension

Need a heel/toe aid for your vintage 911? Why not follow the factory lead?   Here is our first reproduction of the throttle pedal extension used on the 1973 R7 ‘Mary Stuart’ RSR Prototype: CNC machined from 18mm marine-grade plywood for long life, this extension will help position the face of the pedal to better utilize the available factory adjustments. These extensions closely follow the pattern and dimensions of the hand-made original and will be finished in black to wear and patina with use like the real thing: Installs with provided screws into the factory pedal face for secure mounting. …

85L / RS Skid Plates are a go!

Well, we’ve just trial-fitted the first run of our skid plates for the plastic 85L tank, and they’re perfect: Finally you can pull that ridiculously cool, vintage RS tank (actually offered in 1970) down from the attic and put it back in service without fear of damage from road hazards. We designed these after the factory Rally skid plate used under the shallow-bottomed tanks, paying careful attention to the proper large radius at the front (for correct visual appearance when mounted), the overall width, and the placement and location of the mounting holes in the trunk floor – to produce …

RSR Rally Muffler Reproduction

We needed some R/RSR and ST/RSR Rally mufflers for some project cars that are running SSIs/heat exchangers (require heat) and after pouring over period photos we decided to convert some Dansk SS mufflers to make what we need. We’ve done a small run of perforated inner, double walled stainless 70mm exhaust tips, blockoff caps, and created our own fixture to install them at the correct upward angle and spacing of the original part: Still researching the correct flat grey coating for these, so if you have any insight there, please let us know!

MSRSR update: RSR Trailing Arm Mounts

Entering the final bit of welding and fabrication (metal-wise) on the Mary Stuart project, and just finished up the RSR Trailing Arm Mount conversion work; here are some photos: These allow the use of 930 trailing arms – needed because of the widened track and offset of the massive wheel/tire combo that the Mary Stuart RSR used.  The 930 arm has significantly more robust wheel bearings than the Carrera arm to deal with the increased loads of a widened track. For this project, we wanted the mount conversion (which is actually a front pickup point relocation as the 930 arms …

Zuffenhaus 3.6MFI

MFI for Mary.

It’s been a while since we’ve updated; as we’ve been quite busy (and thankful for that!)  since our last post. We’ve been sorting our Celette benches, adding some in-house prototyping capability, continuing physical upfit (construction) of the facility, and making some strides on the Mary Stuart RSR project. Let’s talk about Mary. She’s getting proper MFI.  (If you know anything about us, you know this makes for big smiles around here.) The engine for this project is a 3.9l based on a 3.6, and as such was not designed for use with mechanical fuel injection, although the mounting bosses for the …

New Friends from the Vaterland!

Zuffenhaus was pleased to meet and visit with our newest friend from Germany this morning: Mr. Stark surveyed the shop for a longtime friend and classic Porsche racer; both are Mary Stuart RSR enthusiasts and are patiently awaiting the first production run of bodywork for special projects back home! Look for an announcement about availability in upcoming months, and we look forward to visiting with our newest friends on our next occasion overseas!

Zuchs on 930 – Aggressive Fitment

You asked for it: more aggressive Zuchs fitment for wide body Porsches. The rise in popularity of the Singer Vehicle Design 911 equipped with the Zuffenhaus-Fuchs (Zuchs!) has drawn attention to the flush-fitting wheel aesthetic within the Porsche community. As a result, Zuffenhaus has been getting requests to configure the 3-piece 17inch Fuchs-styled wheels more aggressively – to really fill out the body work and get as much ‘dish’ (deep outer lip) as possible. Here’s the result: Front 3/4 view Rear 3/4 And a side view to show off the RSR Finish. 😉 Let us know when you are ready …

MSRSR update.

Just some quick shots of installation work on the Mary Stuart project: You’ve seen the rear quarter panel and flare (shown here from a couple of angles) – and the front is turning out very impressive as well! This is about how much sheet metal is removed when installing this front flare: And the same for the rear: Nice.

Old World Craft, Quality.

We were asked in class last night (you folks don’t take night classes to stay current on technologies and methods that affect your skill sets?!) if any of us were familiar with casting techniques. Of course I am, as a result of my background – but Zuffenhaus is as well. In addition to needing mold-making experience to design and execute the Zuffenhaus Mary Stuart RSR body panels, we also made the decision to base the Zuffenhaus 2.8RSR Calipers on castings, as per the originals. Although the alloy and post-pour techniques have improved over the years, the base process has been …