Olsen Spec Projects

[danski0224]

Caulk and paint make you the welder* you ain't.

*: Carpenter also works here.

 

[olsenmotorsports]

Targa update. The wing is finally almost done. What a pain. Probably the hardest thing in terms of complexity that we have ever made. Easy for some of you guys probably but for us it ended up being very challenging.




Rear gurney area looks simple, but the compound curves with the tip in turned out to be challenging for us.




This transition also took a bit of time. Shaping from the leading edge of the tail up and over and then back up again to the louvre. Also the louvre is glass so that had to be grafted in



The rear section is shaped. Now all we have to do is cap it trim it and start the final welding process.



We have almost 3 weeks time into this tail section. I know it doesn’t look like much but I cannot wait to see it all done and together.

I am not personally a fan of the tail, but it does give it more of a fighter jet profile. We went off google images (this is a blue angels tribute car) and the wing profiles are were we drew our inspiration from. Quick sketch of it on the render so we know what to build and then it is off to the races!

Thanks for following along! Hope it all makes sense!

 

[danski0224]

Yeah, that is NOT easy at all.

 

[Scuderia-F1]

All part of that Japanese scene!



So I am probably going to get a lot of S**** for this. But I have an incredible amount of respect for RWB. They do not align with me in terms of “how I would do it”, but as a business guy heavily involved in what I do (creating and building cars etc), I have a massive appreciation with what they have done. It is no easy feat to take a radical Idea, execute it, create a cult following, and create elusiveness around your brand. They get a lot of hate from people, I for one applaud them. I am happy for their success.

In my opinion there is never an excuse for a ****** executed job. I see your points and I can to a certain point agree with you. But it says more about the followers than the prophet in my opinion in this particular RWB case.

 

[Scuderia-F1]

So on the 993’s the magnesium racks are kind of a PITA to rebuild. Got tired of fighting with the seals on those things. Tool time!



The location of the seal is 12” down this hole and is a Merkel.



Whipped up a quick seal driver in the lathe out of some spare tool steel we had laying around (aka Old off road shock lol)



Here it is with the seal installed. Will make quick work of these in the future.

I always make/have made 2 of everything. One goes in my personal box and the other is for the workshop.

Also designing a tool for the air cooled fans to squeeze the rivets in with an arbor press. Will share that once it comes back from machining!

Pure gold that one!

 

[olsenmotorsports]

In my opinion there is never an excuse for a ****** executed job. I see your points and I can to a certain point agree with you. But it says more about the followers than the prophet in my opinion in this particular RWB case.

Could not agree more. If these were civic’s we would be having a different conversation lol!

Pure gold that one!

You ever had to fight with that seal? What a pain. I still haven’t figured out what tool to use to remove it. Always seems like I have half the tool box out and it comes out in pieces.

I will show you my air cooled fan rivet squeezing jig for those 5x16mm rivets on the engine?. Pretty sure you are going to like that one.

 

[Scuderia-F1]

Could not agree more. If these were civic’s we would be having a different conversation lol!


You ever had to fight with that seal? What a pain. I still haven’t figured out what tool to use to remove it. Always seems like I have half the tool box out and it comes out in pieces.

I will show you my air cooled fan rivet squeezing jig for those 5x16mm rivets on the engine?. Pretty sure you are going to like that one.

Yeah and I’m gonna have someone make me one of those seal drivers (I don’t have a lathe unfortunately), got all excited read about that rivet tooling project.

 

[MadeByMiller]

Add me to the list of viewers grateful to have you here and posting! I enjoy seeing the excellence in craftsmanship and reading about your philosophy as a business owner.

In regards to your latest tail section postings (absolutely fantastic metalwork!) and your remarks of the challenges your shop has faced with it, I wanted to share a service/technology that I recently discovered while at SEMA a couple of weeks ago. Saltworks 3D is offering CNC sheet metal forming services, Webpage here. While there is no doubt your crew is fully capable of continuing to form pieces like the tail by hand, I thought something like this would be an aid to your shop.

I had a brief conversation with a representative of Saltworks 3D and learned that they use 3D modeled surface bodies to generate toolpaths and program the CNC machine. While a part such as the tail you're working on has it's challenges in terms of 3D modeling, it's likely more efficient to create (and iterate/modify) in digital form than on the English wheel. I mean that in the most respectful way possible for the record - CNC will never replace handmade craftsmanship.

Speaking of 3D modeling, I'd love to be a part of an Olsen Spec build if ever your need arises for another CAD designer!

 

[olsenmotorsports]

Add me to the list of viewers grateful to have you here and posting! I enjoy seeing the excellence in craftsmanship and reading about your philosophy as a business owner.

In regards to your latest tail section postings (absolutely fantastic metalwork!) and your remarks of the challenges your shop has faced with it, I wanted to share a service/technology that I recently discovered while at SEMA a couple of weeks ago. Saltworks 3D is offering CNC sheet metal forming services, Webpage here. While there is no doubt your crew is fully capable of continuing to form pieces like the tail by hand, I thought something like this would be an aid to your shop.

I had a brief conversation with a representative of Saltworks 3D and learned that they use 3D modeled surface bodies to generate toolpaths and program the CNC machine. While a part such as the tail you're working on has it's challenges in terms of 3D modeling, it's likely more efficient to create (and iterate/modify) in digital form than on the English wheel. I mean that in the most respectful way possible for the record - CNC will never replace handmade craftsmanship.

Speaking of 3D modeling, I'd love to be a part of an Olsen Spec build if ever your need arises for another CAD designer!

I appreciate that. Really do. I have been wanting to make the leap to 3d modeling etc. but I need to find the right guy to hire in house to make it happen. I personally have way too much going on to learn something new. But I am a realist and I know if we don’t start then we are just craftsmen stuck in a bubble about to burst.

Thank you for the link. I will look into it.

 

[olsenmotorsports]

Back on a plane today headed for Naples. Looking forward to a quick 10 day break from traveling. Spending some time with the wife and enjoying thanksgiving week. Took a few shots before I left.



Last thing to wrap up is the targa side skirts. Alex bent up some flat stock to the profile of the car.



Here is the transition to the front fender. These are going to be one piece. And will be held in with the 964 body clips. Those are pretty heavy duty and replaceable. Bolting would be better but that outer sill is sealed. So had to get creative.


Rear was templated out. And ready to tack by the time I left.



The rear flare to fender transition he shrunk with the linear die then hit it with the other planishing hammer to get the profile he wanted.





The footprint the English wheel takes up is massive. Then you add the two planishing hammers onto it and it’s just crazy how much room it takes up.

We do have new equipment inbound. So excited. Should be here by thanksgiving.

Baileigh made us an offer we couldn’t refuse so I sent the money over today for their shrinker/stretcher’s. We will be getting both the Mss-14f and mss-16f.

Thanks for your support

 

[WoodsTruck]

We get hammered on safety where I work.
Personally, I would clean up the corners of the caster supports under the car and clean up the sharp edges in the rectangular tubing as well. Anything that you can contact without paying attention and get hurt.
Also, any reason not to drop an air hose down to the planishing hammer to get the trip hazard off the floor?

 

[olsenmotorsports]

We get hammered on safety where I work.
Personally, I would clean up the corners of the caster supports under the car and clean up the sharp edges in the rectangular tubing as well. Anything that you can contact without paying attention and get hurt.
Also, any reason not to drop an air hose down to the planishing hammer to get the trip hazard off the floor?

You bring up a good point. I really need to get better at identifying better safety practices. Thank you very much for bringing this up.

Haven’t done the drops on the hammers yet as we are moving them into the new fab shop in a couple months. No other excuse other than that.

Moving them in April and then we are redoing our entire air system into a closed loop 2” feed.

Thank you for holding me accountable on safety! We try really hard but there is always room to improve. Appreciate it!

 

[olsenmotorsports]

Flew down to Florida last night to see the wife and spend some time with her for the thanksgiving holiday. Started to snow on the way to ORD lol. Super grateful to have somewhere warm to spend the frigid months!

Tires came in for the Bronco Raptor. Was able to get them mounted up before I left. Media had some fun with that one.



My media manager did this while I was out on the Snap-On truck doing some shopping. Came back in and immediately LOL’d. I guess we should have built a safari edition 930



Just goes to show you how big these 37” tires are. Insane when we are used to small stuff!

I had the green audi over at pain getting the front end repainted. It had a couple of small rock chips that were driving me crazy. Then it is getting clear bra done, then ceramic, then getting shipped to the Florida house for the wife (it is her Xmas present) Dropped off the bronco to get a couple rock chips repaired, once its perfect we can start tear down and get that thing built! I really want to have it in FLorida for February but I just don’t think with my schedule of travel and work that I am going to have the time. I think that is going to be more of a summer project for me the way it is looking. That is hard for me as I am super impatient, and have all the parts to do it. Between business, family, continuing education, the boys new houses etc there is just zero time for me to do “me stuff”.

I could have the staff do it, but I drew a line in the sand when I started the business that if it wasnt making money we don’t do it. Sure does apply to my personal vehicles

 

[WoodsTruck]

And I thought you had already started on the Safari model.

 

[gregs]

What field is your continuing education for?

 

[gearhead1960]

We get hammered on safety where I work.
Personally, I would clean up the corners of the caster supports under the car and clean up the sharp edges in the rectangular tubing as well. Anything that you can contact without paying attention and get hurt.
Also, any reason not to drop an air hose down to the planishing hammer to get the trip hazard off the floor?

Maybe not so obvious to some is the cost of doing business and one of those is insurance (a long 4 letter word). In the industry I work in (Survey and Utility Mapping) we are rated on our safety practices and record by the insurance industry. We get a rating and if this is above industry standard, it can hurt us on large contracts, both in the ability to win them and to keep the ones we have. On top of that, if our rating goes too high, it can make us uninsurable or prohibitive in cost. Relaying that to your shop, I would think that your insurer as a practice would visit your location on occasion to see what safety practices you employ along with the general safety of the working conditions. It's in their (and your) interest to reduce risk. Making sure your shop does not have any recognized safety hazards or even unrecognized ones, may go a long way to keep your insurability along with reducing the cost of insurance. I would even push your insurance provider to inspect your shop (maybe after you do your own risk assessment and fixes), make recommendations of how you can reduce your risks and push them to apply discounts that would apply to your diligence and risk reduction. But wait a minute, I'm talking to the choir, you already did all this.

 

[olsenmotorsports]

What field is your continuing education for?

Unfortunately nothing cool lol. I set aside blocks of time 6 days a week for learning. 3-5am every day M-S (Sunday is my time lol).

Monday Wednesday and Friday is business development for myself. This time is spent online classes or research on a few topics. Leadership skills (I used to REALLY ****), business growth and strategy, growing a team, preparing business for scaling/selling, succession plans, systems and process's etc.

Tuesday and Thursday is research on new products, better hardware, fluids, tooling etc. Basically anything that can level us up or improve our efficiency so we can increase bottom line profits as well as top line revenue.

I have to do it during these hours, as soon as the wife and dog wake up that is their time, followed immediatley by whatever the business requires of me.

For me, if I can put in 2 hours a day, 6 days a week 47 weeks a year, that is 564 hours a year that I am working on improving myself as well as my store. Even if my competition puts in half of that at some point in time I would surpass them and then they will never be able to catch me. This all came from what I spoke of before. I dream huge, and I am overly competitive. There is nothing I will not do to win. I wanted my brand to eventually become the benchmark (however long that took), and I knew that in my current knowledge level I wasn't capable of doing that. This all started about 3 years ago. Just got tired of riding the struggle bus to nowhere.

Thank you for the comment!

 

[gregs]

Thats impressive. How much sleep do you get? I am guessing that your overall health is at the top of the list as well?

 

[olsenmotorsports]

Maybe not so obvious to some is the cost of doing business and one of those is insurance (a long 4 letter word). In the industry I work in (Survey and Utility Mapping) we are rated on our safety practices and record by the insurance industry. We get a rating and if this is above industry standard, it can hurt us on large contracts, both in the ability to win them and to keep the ones we have. On top of that, if our rating goes too high, it can make us uninsurable or prohibitive in cost. Relaying that to your shop, I would think that your insurer as a practice would visit your location on occasion to see what safety practices you employ along with the general safety of the working conditions. It's in their (and your) interest to reduce risk. Making sure your shop does not have any recognized safety hazards or even unrecognized ones, may go a long way to keep your insurability along with reducing the cost of insurance. I would even push your insurance provider to inspect your shop (maybe after you do your own risk assessment and fixes), make recommendations of how you can reduce your risks and push them to apply discounts that would apply to your diligence and risk reduction. But wait a minute, I'm talking to the choir, you already did all this.

Don't even get me started on insurance. We have been stuck in specialty insurance for a decade until this year. My insurance is over 6 figures to put that in perspective. 10 years of zero loss runs, zero workers comp claims etc. We build/restore custom Porsche's. As soon as they see that they run.

It wasn't till this year when a door knocker came, saw our space and all our safety regulations in place and finally wrote us for standard insurance. Before that we bounced from K&K, Loyds of london, and Kinsale. All last resort style places.

Now we are with Hagerty, Still a huge cost but it is starting to come down. If they guy had not seen the operation in person I don't think he would have taken a chance either.

I still need to get better with safety, we run a tight ship and keep everything absolutely spotless. but to your point it is always the things you DON'T think of that always bite your behind.

 

[olsenmotorsports]

Thats impressive. How much sleep do you get? I am guessing that your overall health is at the top of the list as well?

Wouldn't say impressive, if I was smart I wouldn't have to do this

I am a 10-2:30 guy. And yes health is foremost. I have my wife to thank for that. Everything is fresh, GMO free, no preservatives, no sugar etc. All the basics.

 

[MadeByMiller]

I appreciate that. Really do. I have been wanting to make the leap to 3d modeling etc. but I need to find the right guy to hire in house to make it happen. I personally have way too much going on to learn something new. But I am a realist and I know if we don’t start then we are just craftsmen stuck in a bubble about to burst.

Thank you for the link. I will look into it.

I see CAD and CNC processes dovetailing very nicely in your shop and the builds that come out of it. I view it as just another tool in the shop, once you obtain the tool and the operating knowledge it becomes more clear how you can utilize it. I began my career and eventually business as a welder/fabricator, so I have been hands on involved with processes enough to understand the digital impact in the shop. Now that I'm doing freelance design work full-time I can lean on that shop background to visualize how the craftsman in the shop will bring my designs to life.

 

[brentmc]

Tim--incredible thread and I applaud your approaches to accountability. As a retired military guy and current fed (many stories with both), accountability is underrated and many managers do not have the courage to be transparent/up front with their staff on this or on expectations...this usually leads to confusion, misunderstandings and mission failure. "The gap between two people's expectations is called disappointment" rings true here. You are inspiring how you approach this and I am encouraged seeing this outlined the way you explained it.

On another note, I winter at our home in Port Charlotte ( 1 hour north of Naples) and am looking at a 911 on consignment in Naples. It is actually my cousin's car but on consignment ( 1981 911 Coupe) to a used car dealer. I am a former muscle car guy (see profile pic) but am moving to a 911 IF I can find one that doesn't need 10K in work right away.

Do you have any advice on buying a G-body from your perspective? I saw recommendations to buy a 3.2 911...I am hoping my cousin's 911 is as awesome as he says (he is a good person) but need to tread carefully into the 911 world as my retired military pay and fed pay are not a deep pockets...

Also—what does an average 3.2 full rebuild normally cost?

Thank you in advance sir.

Brent

 

[olsenmotorsports]

Tim--incredible thread and I applaud your approaches to accountability. As a retired military guy and current fed (many stories with both), accountability is underrated and many managers do not have the courage to be transparent/up front with their staff on this or on expectations...this usually leads to confusion, misunderstandings and mission failure. "The gap between two people's expectations is called disappointment" rings true here. You are inspiring how you approach this and I am encouraged seeing this outlined the way you explained it.

On another note, I winter at our home in Port Charlotte ( 1 hour north of Naples) and am looking at a 911 on consignment in Naples. It is actually my cousin's car but on consignment ( 1981 911 Coupe) to a used car dealer. I am a former muscle car guy (see profile pic) but am moving to a 911 IF I can find one that doesn't need 10K in work right away.

Do you have any advice on buying a G-body from your perspective? I saw recommendations to buy a 3.2 911...I am hoping my cousin's 911 is as awesome as he says (he is a good person) but need to tread carefully into the 911 world as my retired military pay and fed pay are not a deep pockets...

Also—what does an average 3.2 full rebuild normally cost?

Thank you in advance sir.

Brent

Wow thank you for the kind words. I agree people are afraid of others perception which kills success. It’s crazy because people just want people to like them, so they tiptoe. Not understanding that accountability breeds respect which in turn makes people like you lol. Crazy right?

Knowing the expectations and getting people involved in the vision/direction as well as boundaries are extremely powerful tools.

Good for you on the winter home port charlotte is great! Love it there.

On the 911, budget plays factors here of course. The 3.2 is better, and if your budget allows the 87 up chassis has the best upside with the g50. Pay more obviously for it, but long term the upside is far greater.

Have it looked at professionally with a PPI. Porsche Naples has a great classic program and Bruce over there used to work for us. I value his opinion.

A rebuild has a great range of pricing, 40-60k. Head over to our website olsenmotorsports.net and throw a submission form in. One of our team will contact you this morning and send you some detail on our engine packages.

Share with us how your experience is with that sales process as well here! (I think you will be impressed)

Thank you very much for chiming in!

 

[jake28]

@olsenmotorsports as part of your continuing business education and for your next flight or roadtrip: I highly recommend the Acquired podcast series. Two reporters go in depth on the history of standout companies. I can’t say enough good things about them. Two episodes I would start with:

Costco

Hermes

 

[olsenmotorsports]

@olsenmotorsports as part of your continuing business education and for your next flight or roadtrip: I highly recommend the Acquired podcast series. Two reporters go in depth on the history of standout companies. I can’t say enough good things about them. Two episodes I would start with:

Costco

Hermes

Than you for that! I actually study Costco in depth as I am a huge fan of their teamwork and throughput. I will check this out and subscribe. Hermes is a brand that I also model my organization after (huge fan of the biz, so is the wife of their products lol)

I also study the ritz and 4 seasons. I am chasing what they have, relatively normal blue collar people all preaching the same message, great customer service and fantastic consistency. Love that about them.

Thank you very much for your input. I am learning a lot here and that is the whole point! You guys are awesome.

 

[tarbellb]

Absolutely love your contribution to the forum, please keep posting the stellar work you all do day in day out.

Also, don't let anybody tell you purple ain't a badass color to throw on a ride

my fav right now- Genesis GV70 matte purple

 

[olsenmotorsports]

Absolutely love your contribution to the forum, please keep posting the stellar work you all do day in day out.

Also, don't let anybody tell you purple ain't a badass color to throw on a ride

my fav right now- Genesis GV70 matte purple

Those are sick! I am a big fan of how Genesis has executed their styling. Good for you that looks amazing!

 

[Wiz02]

Those are sick! I am a big fan of how Genesis has executed their Rolls Royce / Bentley styling. Good for you that looks amazing!

FIFY

 

[olsenmotorsports]

Enough boring *** business talk. Back to cars.


IDK why I cannot stop staring at this photo. Really pleased with how the 930 is turning out. The curves really are incredible for making this off of a photo render. So proud of the team.



Wiring is 100% done and tested. As soon as we can we hook up a battery and start testing circuits and switches and grounds. I have dedicated loads from 3-10amps that we hook up as needed to simulate a load. Really makes a difference when you test as you go. We used to build them and then test (some times that worked, often it was a **** show lol) The product is only cherry once, and if you have to start taking things apart it never looks the same.



The rest of the sound deadening is in. If you guys ever get a chance to use Soundshield I highly recommend it. That goes everywhere. Just make sure to glue it when you put it on the roof as the adhesive will not hold in 90 degree weather (learned that the hard way lol)



Fuel system is installed, plumbed as far as we can take it, and of course a new Porsche Classic fuel filler cap.



The brain for the active shock absorber and front lift system is installed and wired. This will get a 2” push button hydraulic front lift installed so getting in and out of driveways and going over speed bumps is easier.



Here was my final render back in June when we started this project. I think the guys nailed it.

Thanks for your support!

 

[olsenmotorsports]

964 RS engine is done with the top end rebuild (Told you guys we are fast with those! It has only been out ten days)



This is a real one. Lots of people online hate and say it “isn’t real” but they do not understand that the customer changed the lights as well as wheels and decklid. Why you ask? Because he can! lol. This guy is my hero.



Paul getting the engine installed. Blessed to have him. He’s young and hungry. Turning into a really talented engine builder. I’m proud of his growth as a mechanic as well as a person. Kid has an incredibly bright future in front of him.



The other side of the shop Patrick is yanking out ANOTHER 911 engine that needs to get turned quickly as well.



He is using our other engine table to get this one out. People Tell me im crazy as I always buy two of everything. But time is freaking money and equipment is cheap when you look at it that way!

Brings up a good point? How often do you change out tooling? I have a rule, if a new tool is out (say compression tester on the snap on truck etc) you a couple right away and put into service. Then you take the old ones and use them as emergency spares so that you are always covered. We buy every 24 months new special tools that are in heavy service. 5 years on light service. This year is one of those 5 so it’s a pill to swallow. But down time costs too much.

Terribly sorry for the bad picture quality. This platform (GJ) is garbage and for some reason it will not allow me sometimes to post the photo (shows uploaded but blank). So these are screenshots.

 

[olsenmotorsports]

Side skirts are done on the targa. Right on time.

We get a lot of S*** online that we are doing it all wrong. Constantly when the comment generator is out (welder) so I stopped marketing from posting them. I dont think It is a good vibe for our fans to see all the hateful comments.

Alex hates stitch welding sheet metal (short increments jumping around) as the final finish takes him longer. He does one pass weld’s the entire way once he is tacked. As long as you can control your heat and path it really is superior as the metal holds the same distortion the entire way. Cuts the hammer and dolly time in half at least. People call him an idiot, a ******* and many say I would never let him near my car etc, (i try and shield them as much as possible from it but it is what it is) But he is so fast. He builds these cars in less than 120 calender days start to finish. And none of the stuff he does would be considered easy in the real world.


Here is the rear cap all done up and welded



Front profile looking down the side of the car. All welded, hammered and metal finished. I think he killed it.



Rear cap done, welded and finished. These are one piece front to back and should hold up for years.

Thanks for following along and happy to answer any questions!



Weld nuts for the front and rear to secure them where we can by the fenders.

Once again sorry for the terrible photos. I am working remote and going off video clips. Clients get videos of the process every hour and I just am downloading them from my home office and taking screenshots! I probably should ask for photos but I feel terrible intruding on them to stop and take me some photos. We will just have to deal with this for now till I get back in town.

 

[stinkity stoink]

I believe the people commenting about the welding are just uninformed about the way things are really supposed to be done. As a novice metal shaper (very novice), it scared the hell out of me doing full welds like that on a panel at first…It was not the way I was taught 30 years ago. After reading and taking a few metal shaping classes and doing it I realized it’s the way to go.
Great thread, thanks for posting!!

 

[olsenmotorsports]

I believe the people commenting about the welding are just uninformed about the way things are really supposed to be done. As a novice metal shaper (very novice), it scared the hell out of me doing full welds like that on a panel at first…It was not the way I was taught 30 years ago. After reading and taking a few metal shaping classes and doing it I realized it’s the way to go.
Great thread, thanks for posting!!

Thank you for the kind words! Yeah I am not sure why people stitch weld. All you are doing is creating more work for yourself. Makes no sense.

Love to see some of your projects!

 

[Chris F]

I am a 10-2:30 guy.

I am always amazed and wonder how some people can function on that amount of sleep. The only time I get out of bed at 2:30 in the morning is if I can't hold it any longer!

 

[olsenmotorsports]

I am always amazed and wonder how some people can function on that amount of sleep. The only time I get out of bed at 2:30 in the morning is if I can't hold it any longer!

Hilarious. To be honest I have no idea. Wife is complete opposite. She needs a solid 7-8 or her day *****. I get 5 tops. Never set an alarm and when my eyes open my feet hit the ground.

I think there is something wrong with me

 

[WoodsTruck]

I seem to do some of my best thinking when I wake up at 2:30.
I don't do my best remembering by the time I get to the desk at 2:45.

 

[36truck]

I've been getting up at 2:30 in the morning for the 3.5 years for work it hasn't gotten any easier. Good thing it's only a few more years. 5:00 am would be so much better.

 

[fozzy]

I've done a couple of 24/7 jobs that required significant shifts in Circadian rhythm. It is never easy! Breakfast for dinner is not so bad though. Waffle House had that one figured out long ago. I prefer 7-8 hours of sleep as well though, regardless of whether or not the sun is up- can't imagine operating on less than 5 hours of sleep for more than two or three days.

 

[olsenmotorsports]

I seem to do some of my best thinking when I wake up at 2:30.
I don't do my best remembering by the time I get to the desk at 2:45.

I've been getting up at 2:30 in the morning for the 3.5 years for work it hasn't gotten any easier. Good thing it's only a few more years. 5:00 am would be so much better.

I've done a couple of 24/7 jobs that required significant shifts in Circadian rhythm. It is never easy! Breakfast for dinner is not so bad though. Waffle House had that one figured out long ago. I prefer 7-8 hours of sleep as well though, regardless of whether or not the sun is up- can't imagine operating on less than 5 hours of sleep for more than two or three days.

My sleep is all hormonal related. Full Clarity I used to be like this in my teenage and young twenties. I used to be able to party all night and work all day. A few years ago I started testosterone therapy. OMG game changer. I am back to my young self, laser focused, tons of energy. When I do sleep it is lights out like I am in a COMA. Nothing wakes me. For any of you high achievers I suggest to get involved in a high end Men's Health Clinic. Will transform your life. (at least it did mine)

I noticed myself start to slip a little at 43, just didn't have in the tank what I used to. Hormones are crazy what they do to your body when they are off just even a little.

Wife is different then me. She can hear a pin drop and wakes up. I think that is why she sleeps longer as it isn't recovery sleep. More resting sleep for her.

 

[olsenmotorsports]

Really sorry for letting this forum get away from me, been an absolutely insane week for me. November and December are difficult being a business owner due to all the planning for the fiscal as well as trying to close the current one. Fun times!

Another cool tool we made. All of the early Porsche’s (68-97) had fans made of two pieces. One part is Magnesium, that is riveted to a hub that is usually 1015. To restore them right you have to do them separate (lol try getting Mag zinc plated lol).

The rivets are DIN 661 in 5mmx16. The issue with the 661’s is that the hub sits proud of the rivet head. We have cracked a couple of fan housings using the traditional air hammer bucking bar. Mag is so soft and brittle and the vibrations from the air hammer just crack it. No readily available pneumatic rivet squeezer will get there due to the size of the lip on the fan. So time to make a tool.


Here you can see the DIN661’s sit under the surface of the plate.


The answer (this is rough right out of the mill, still needs to get tumbled and then sent to plating to get the “olsen spec” finish for a tool).

We plotted the rivet pattern and milled in 6 standoffs on a disc of tool steel. The inside chamfer on the disk holds the plate of the fan from moving around.



Plan views. Yes those are zinc rivets which don’t exist. I buy them in the 2k quantity, then have them zinc plated so everything matches. Once again I am ****!



The pins hold the rivets in place perfectly. That coupled with the inside chamfer allows you to place all six rivets on the jig and squeeze them in a star pattern without having to remove the plate from the jig.



All that is left is to machine in a hole on the bottom of the arbor to Receive a rivet set. Going to also machine in a set screw from the side to hold the set from falling out. Then send everything to plating so we can put this into service.

As always, we made two. One for the shop, and one that goes into my tool box. (Second one is on the countertop behind arbor press.

Seems like we are always making tools and it never ends.

Happy to answer any questions! Happy Thanksgiving!