Well I've been browsing on here for a while so thought I'd post up a few photos of my little project.
(This has all been copied from my project thread on another forum so sorry for it not being straight forward!)
The Ad photos:
After looking at a few nasty 944's I found this little (soon to be) gem on car and classic. It was up for £1700 with a power steering leak, no MOT and Sorn'd.
I decided to bite the bullet and go visit under the impression that it might be a dog like the others but was cheap. I knew it would need work as it was half my budget but for a car that was potentially good I thought it would be worth going to see.
Saturday my Dad and I went to visit a lovely couple in their 60's, they were running around flapping around the car trying to get it to start again. It was all hot so we knew it had run but we couldn't get it running after.
Looked round it with my Dad, both pointing out faults with the car. This I think then scared the woman into thinking it was better off scrapped which made her say "take it away for £1k" We carried on looking around and ended up snapping it off them as the faults we have aren't crazy bad and £1k is an offer we couldn't refuse!
So now have £2K to sort the thing out!
So Sunday we picked it up:
Back home:
So that's it so far, we are now in the process of trying to get it to run. We are vaguely in the right direction as the tacho isn't bouncing which it should so this can point us in the right direction in terms of ECU/Sensors.
Now to get it started and whack it in for its MOT!!!
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We then got it started!
It was misfiring to start with so a clean of the dizzy and some new plugs sorted that!
New Steering rack which got fitted
Also a few photos of it when I moved it on the drive.
New lights:
Bit of an update...
Taken it out quite a lot in the last couple of weeks! Been driving it every day and clocked up quite a bit of mileage considering it only gets used in the evenings
So here are a few photos of it out and about!
I also fitted some new mirrors to the speedo and new LED bulbs to give the dash a bit more light!
and fitted my headunit from the corsa to replace the pooe radio and tape player :lol:
Then today I gave it a much needed clean!
Then took it to show my dad where I recieved a large knocking coming from the rear...
I think my Dad was happy to look at something other than a Vauxhall for once. Got it on his drive and next thing I know he's got the jack out and got it up in the air!
It seems like the Outer CV or Bearing has eaten itself as it is knocking A LOT from that area. So got it back home and will be taking that all apart during the week!
Sorted the CV and bought new seats
Out with the old in with the new
A few mates and I went out last night for a bit of a drive.
We went to a tunnel in the middle of some lanes so thought it would be rude not to see what the cars sound like in one...
Mine is the second car. The first is a 328 E46 and the last a Focus ST.
Not the best update but at the start of the month I bought some mats for the car which have now arrived
and my Dad gave the leather a bit of a clean up today as he wanted to try out some Auto Glym he'd bought
Well this week end the car got a clean and clutch bled.
Yesterday we got it in the air and bled the clutch...
Unfortunately old braided hoses don't like it when you put an Easy bleed on them! The hose went pop from the master cylinder and chucked clutch fluid everywhere!
Whacked a new bit of braided line on and it was good as new
We went to brooklands and got some photos on the old bends!
Pictures aren't the best and the car is pretty dirty but better than nothing!
These were also picked up:
and then put on...
So now the car needs a little bit of lows on the front which might happen tomorrow evening...
Probably play with the rear as well but may need to work on that a bit more when I get better rear shocks.
Got a few photos yesterday whilst the weather was nice and also fitted porsche badges to the wheels
So that's it to now, got a turbo front end for it ready to be sprayed up after we do Nurburgring in August!
Thanks for reading (If you got this far )
Woops...
This came up cheap locally so snapped it up!
Wasn't planning on getting the bits soon at all but my step dad spotted it so picking it up sunday. Still got bits to sort but it won't be in until late next year when I'm happy it's exactly how I want it
UPDATE
Taken from another forum...
Well as some of you may know I went to the Nurburgring last week. We left Saturday and came back the early hours of yesterday.
The car was literally fantastic. It drove there and back and got a good pounding whilst there with no issues!
On the way we stopped off at Spa to see the GP Track and then carried on to Germany on the Sunday. We then spent the week roaming around parts of the ring, karting and generally site seeing.
Whilst at subway and karting we bumped in to OJC (Ollie) off here which was funny!
Before we left a Mate and I had decided we'd sticker some helmets up for a laugh and whack some names on the car.
Right enough talking here's a few photos of the car and some bits. (I can't be arsed to post up how many thousands of photos I have so only put a few in)
UPDATE
Finally a Car update!
As some of you may know/remember I bought a Turbo front end ages ago that I hadn't got round to fitting/spraying.
The time has finally come to get it sorted. So yesterday I set about getting the old stuff off and the new stuff on!
The photos do the talking...
New indicators front and wings.
Intercooler hole....
Redundant parts when swapping to a turbo front end!
Placed on.
Lining up
First Cut
Giving it some shape
Cut wing
The old wiring was a bit tatty as you can see so I bought some new Kit car connectors and made up a new bit of loom.
It was dark when I finished tonight but got all the lights working just need to attach the bumper properly then I can take it for paint so they can finish off the edge on the wing and obviously sort the colour out :lol:
Slowly coming along though
Should be sorting Paint over the next couple of weeks
UPDATE
I got some better photos of the interior...
Oh yeah...
Well after a week away she's back from paint!
So next task was fitting the bumper with the lights and new clear lenses
So then I went out to get some better photos with the whole car with a couple of mates.
Just need to get the back down a bit now when I get my Coilovers after Xmas.
Well I got these:
Off for powder coating with the backs in Jan
Boxing day the clutch master cylinder decided it was no more.
So bought another one which arrived yesterday:
I've also got a few extras ready to go on the car:
Quickshift Gear Linkage as my old linkage was worn
Also going to be making a rose jointed bar for the linkage arm using this track rod end from a Go Kart:
I've also had a bit of play in the steering column for a while.
The bearing I tried to get from Porsche a while back but they had discontinued it. Luckily on one of the forums I was able to get hold of one a guy hadn't fitted to his after buying it from Porsche a while back.
The white bush is for the bottom of the gear linkage so hopefully the whole mechanism will be brand new once I've sent the linkage at the bottom of the stick off to be reconditioned.
The car's off the road for the next few weeks. It's up in the air on stands at the moment. I've got the callipers off and getting the new ones powder coated over the next week.
Hopefully have the new parts on over the weekend if I can brave the rain again.
Well its that time again.
Quite a few more bits have come. Only waiting on one more bit then I can get the car road worthy again :nod:
So...
New braided lines
New discs and pads in these boxes...
New genuine Porsche calliper seals
and the best bit...
Callipers back from powder coating!
and then after some stickers...
Should have some more updates on the car after the weekend.
Now it's up to date Enjoy!
UPDATE
Well last weekend I got the old girl back on the road.
I didn't take many photos as a lot of the time I've spent working on it has been after work in the evenings.
Here's what I have done and a few photos:
I changed the lower bearing in the steering column which was a right pain in the . To do this you need remove most of the dash
I also changed the whole rear linkage setup for the gearbox for the rose jointed stuff and made an adjustable bar to replace the horrid old one.
Refurbed gear lever:
Old support bar for the linkage:
I cut down a Go Kart track rod end and re tapped the bar with the rose joints to replace the old one:
I then rebuilt the callipers:
I also got the brakes new pads and discs on.
I then took it for a drive to a mates last sunday:
It was great to drive and everything was so much more precise! Great to see my hard work had paid off :thumbs:
Today I drained the old gearbox oil and put some new stuff in.
This definitely hasn't been done since it left Porsche in 1986.
Then filled it up:
So that's where it is now. Going to roll the rear arches tomorrow and lower the back down a bit.
UPDATE
After doing some minor jobs that needed sorting I washed the car today.
Took it out for a late afternoon blast with a mate so got some photos during a stopping point.
It's booked in to a Porsche Specialist on the 27th to have the rear arches rolled so I can bring the back down with some new suspension
UPDATE
Well the coilovers arrived Thursday. After opening the box I realised there was a mix up with the rears so they've been sent back and are getting sorted free of charge thanks to the guy who's helped me get them.
Whilst still eager to see what the fronts looked like and the fact I'd sold the existing setup I began to strip it down yesterday...
We got it in my mates Garage/Massive Gazebo!
Said new front coilover
We then got the front stripped down for re-assembly
After we had the coilover in the top mount we then ran into an issue with it not mounting to the hub.
We're now waiting to contact GAZ monday to see how they suggest to sort it. So currently it's sat like this
We decided not to waste time and crack on with getting the rear torsion bar ready for the rears so after some adjustment we got some lows...
And an overall shot of my mates garden... I'm so jealous of the space he has!
*****UPDATE*****
I rang GAZ monday and they gave me the good news that the coilovers were ready!
So last night I went round to my mates where the car has been for the past month.
Instagram "I'm finished" photo
Also yesterday my rear valance arrived:
Today I spent most of the day sorting some brake ducts which were basically left over bits off of my Step dads Cobra so was a slight make it up as I go along job....
Quite well hidden, you can't see it at all when you actually look at the car.
It's not quite settled yet and we've got to play with the torsion bars on saturday so not quite the final height yet but you get the idea!
*****UPDATE*****
Came back from the 'ring yesterday after 10 days and 7 laps over there with a bunch of mates.
The car performed brilliantly and the suspension and brakes have made it 100% better than last time!
Any way a couple of photos I've found so far...
Will post more photos and videos when I get on a PC
*****UPDATE*****
So I thought I should probably update this...
I fitted a turbo rear valance just before Germany once it was painted, theres a couple of photos from Germany and also I got a 996 GT3 Cup Car steering wheel fitted in there.
I've been busy working on the trip video which will be up soon :thumbs:
...and also might have got the engine stripped down for it's rebuild... :cool:
Anyway enough of the boring stuff, here's a few photos!
So a few photos to update this:
The engine has continued being stripped and put on the stand:
That will be being stripped fully this week so next month it can be rebuilt.
I've had a knock coming from the front since I got back from Germany, it looked to be top mounts so replaced it with these that appear to get good reviews on the Porka forums:
New front tyres should be coming wednesday so I'll get them on and get the geometry checked/adjusted accordingly. Hopefully it's not thrown it out too much!
I hope it to then be ready for Combe where it'll be out on track :cool:
*****UPDATE*****
I got the engine stripped down more yesterday:
And obviously needed to show the size of the pistons by fisting it... :lol:
A few photos from going out this evening
Also the engine is coming along nicely! Its starting to go back together... I've been pretty slack on photos. I'll get some when I'm next out working on it.
*****UPDATE*****
So a bit of work and purchasing has been happening.
I got the sump off to get to the big ends and crank:
With the girdle set up these cranks don't tend to wear much. I decided I'd see if it needed a regrind.
Using a plastiguage I measured the cranks tolerance. The factory specs are between 0.038-0.07. as you can see below mine was better than that. Each one actually measured 0.025
It's safe to say only shells/bearing will get changed.
I got the engine cleaned down and painted.
I also bought 2 more goodies
Yup a new gearbox and Diff.
I bought an S2 gearbox as it has hardened gears like the turbo box but is closer ratio than the turbo so should make it a bit quicker through the gears. The standard gears feel slightly too long for track/acceleration as it's really made for autobahns.
I've now got the full rebuild kit, exhaust and various other parts I was missing so it won't be long now.
*****UPDATE*****
So the parts have been building for the engine.
I went to Trax a few weeks ago. Was a good show as always. On the drive home I found myself pulling over down a random road to lots of smoke and what I thought was going to be a fire :0
After getting it home it was clear the water pump had given up the ghost and an oil leak on the Cam housing.
Normally I'd simply replace these parts and carry on but as I knew the engine was so close I thought I'd just start getting it stripped down a bit earlier.
So got it on some ramps at my mates house and started pulling it apart the day before combe.
Gearbox out
Got all the curse word off the underneath of the bonnet
Got the gearbox back from having the LSD fitted to put some paint on it (It's a tad lairy )
The clutch on the car has never been fantastic since I've had it and it's always felt like I have driveline shunt.
I read on the internet a year ago about the rubber in the clutch giving way over the years which is why you get the driveline shunt. Lots of people carry on driving them as a clutch job is an expensive job. I was always changing the engine out so thought I'd use it until it went bang.
Well as you can see from the following photo my clutch was well and truly ruined! It's still the clutch that was fitted in 1986 as the clutch got updated to no rubber after a few years of its release.
So 2 ring trips, lots of abuse from me and 134k on the clock I don't think it did too badly...
The amazing thing being that it still has a tiny bit of meat left on it :lol:
So that's almost where it's at.
Currently waiting on a few parts then I can get the engine back together.
Hopefully won't be off the road too long, I just want to get back in it :nod:
*****UPDATE*****
So I've spent this weekend getting the engine built up so it can be moved to the car.
Not got too many photos but this weekend has consisted of lapping valves, reassembling the head, adding pistons to the block with new rings, new bearing on the crank, head gasket, head put on to the block, cam housing put on to the head and then some tarting up of parts and refitting with new gaskets.
Anyway a few photos:
Hopefully more to follow through the week.
*****UPDATE*****
So this is an update I've been waiting for.
Got the engine to my mates house where the car is:
Had a few minor hiccups involving it going in and coming straight out but now she's in to stay:
Now as some of you may know, I've had a few tricks up my sleeve regarding the setup of this engine. I've gone for a quick ratio S2 gearbox which is now full installed.
I've gone for a K26/6 hybrid turbo which will help with a super quick spool and make decent power with the perks of a smaller turbo charger.
I've also bitten the bullet and gone for a full ECU setup from Augment Automotive which are starting to make more updated, better products for these cars. This will allow me to have full logging capability, 3D mapping and able to bluetooth to my phone to use as gauges - This function won't be used on my car.
From what I've read it really is quite a bit of kit. Currently just waiting for the final bits to be sorted for it to come.
Here's a few photos Tom (the guy who runs the show) has sent me:
Old Vs New Turbo and new waste gate.
So hopefully will receive these bits this week.
*****UPDATE*****
So we've been working on the car most nights this week and all weekend.
Unfortunately we've had a lot of reworking due to not remembering which bits came off first :facepalm:
The turbo arrived so we set about getting it sorted, it got mounted up then had to be taken off and put back on due to some pipe work that had to be bolted up first.
Over the week we've got the following done:
Turbo mounted up with pipe work
Intercooler piping fitted
inlet and fuel rail etc fitted
alternator, air con pump and belts
gearbox filled with oil
manifolds and exhaust system finished
bonnet back on
badge panel back on
wiring finished apart from the turbos water pump
sorted the dash out
lots more I've forgotten about.
Any way here are a few photos, unfortunately have been pretty slack so not got any of the current state.
So that's almost where we are, looking to get some more done over the next week.
*****UPDATE*****
So the last few days have been eventful.
Got the ECU and last parts for the car Friday. Got the car all fixed up and ready to start bar fluids.
Topped it up with oil and put some water in, immediately had water pouring out the block. After a horrific amount of cursing and a very late friday night we had found the leak on the water pump due to me not getting all of the the ol gasket off the block :facepalm: :facepalm:
So got that all that back together and had it fire up yesterday... for 3 seconds. Hasn't started since but currently being helped with the mapper Tom to try and sort it out. The ECU logging shows that everything seems right that end so only time will tell. We've got spark, fuel and compression so must be a spark timing thing or overfueling I guess.
Anyway here's a few photos:
then it was like this:
Thankfully now looking more like the top photos.
*****UPDATE*****
So felt I should probably update this.
After getting it back together last friday and saturday it took its first drive saturday afternoon :cool:
Not much to report other than it was pretty fun taking it out for the first time!
So I've been desperately trying to rack up the milage to get it run in. Up to 400 miles now but half broke it today so going to fix it tomorrow and finish the 500 tomorrow.
It's going for mapping sunday then I can see what it really feels like :cool:
a few photos:
Clutch release bearing was our fault :facepalm: a slight installation error but appear to have sorted it now.
Was nice to get it home
So after driving it and gradually upping the revs it developed a bit of a boost leak.
Turns out it was from the bottom of the inlet so had to reseal that Tuesday
I drove in to work the next morning after sorting it and it scared me shitless :lol:
Boost came in hard and heavy at half throttle and got the back twitching :0 ... Yeah this is going to be a bit of a monster...
So the running in has been going well and really making me grin. Today I set off to get a boss welded in the exhaust for a lambda for sunday. On the way there a coolant hose decided it didn't want to hold water again so had to get a friend to tow me the rest of the way and home again :lol:
Got the boss welded in and will have a new hose tomorrow. Hopefully will get it ready for mapping and then I can see it's true potential!
*****UPDATE*****
So I sorted the water hose that had split and got the final 100 miles done. Did an oil change and put some proper coolant in it.
Then I got it mapped sunday. Got there with no issues. Took it for a gentle drive with Tom (the mapper) and he started ironing out the uneven bits of the map. We then got it on a long bit of private road where we were able to do it's first pull of the rev range. Immediately ran into our first issue. It was over boosting as the map was set to a 1 bar boost limit.
After upping the limit we did another run where we achieved a steady 1.2 bar of boost.... I ended up bottling the end of the pull because it was climbing rapidly in 3rd gear like it was 2nd
After a few issues like boost hoses popping off and losing alternator tension we went for a last pull.
Now we had connected the vacuum hoses properly we were now not losing any boost, achieving a lot more than both of us were expecting... This is now too much for the injectors. We've maxed out the injectors for a full rev range at 0.8 bar of boost - it starts to run lean on more boost.
Tom had a look online and people are claiming the standard injectors are good for 270WHP but we're not sure it's quite making that power.
So now we've left it on a safe map at 0.8 bar with the intention of upping it after xmas with new injectors and a lambda sensor which should see it making some really good power.
Delivery is pretty good at the moment but the trouble is I know what it's capable of now...
So got it home after a few issues and then I broke it right outside my house :facepalm: It's managed to loosen the power steering pump bolts and shims which have fallen off. So now got new ones on order from Porsche. Hopefully should be here in the week.
I'll get videos on the weekend :thumbs:
*****UPDATE*****
So after the last update we had a few issues.
We took it out and broke it, the wastegate had worked itself loose. We'd also noticed it was also blowing from the turbo... Great.
This meant taking off all the ancillaries to get the turbo off to change the gasket/work out why it was blowing.
Whilst dismantling it we'd found a few bolts also loose. After a long think we decided to check the timing of the balance shaft belts as we were thinking it may be rattling itself loose.
After discovering that the balance shaft belt had worked itself slack and had moved timing we were sure this was causing our issues.
After a few nights work we had it running again. It was running sooo much smoother. Since then I've been just giving it a bit of curse word and it seems to be taking it quite well. I had a problem with the starter motor but that appears to have been sorted now as we had discovered a leaky slave which was leaking on to it.
So sorted the slave and have just been driving it to see how it lasts.
I've now got an issue with a CV joint but that's kind of expected seeing as it was probably the original one on the car....
Anyway enough text. Here's a quick video of it.
We hooked a mic to the outside of the car and used the onboard sound as well.
I hope that has made some vague sense…
Any comments are welcome!
(This has all been copied from my project thread on another forum so sorry for it not being straight forward!)
The Ad photos:
After looking at a few nasty 944's I found this little (soon to be) gem on car and classic. It was up for £1700 with a power steering leak, no MOT and Sorn'd.
I decided to bite the bullet and go visit under the impression that it might be a dog like the others but was cheap. I knew it would need work as it was half my budget but for a car that was potentially good I thought it would be worth going to see.
Saturday my Dad and I went to visit a lovely couple in their 60's, they were running around flapping around the car trying to get it to start again. It was all hot so we knew it had run but we couldn't get it running after.
Looked round it with my Dad, both pointing out faults with the car. This I think then scared the woman into thinking it was better off scrapped which made her say "take it away for £1k" We carried on looking around and ended up snapping it off them as the faults we have aren't crazy bad and £1k is an offer we couldn't refuse!
So now have £2K to sort the thing out!
So Sunday we picked it up:
Back home:
So that's it so far, we are now in the process of trying to get it to run. We are vaguely in the right direction as the tacho isn't bouncing which it should so this can point us in the right direction in terms of ECU/Sensors.
Now to get it started and whack it in for its MOT!!!
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We then got it started!
It was misfiring to start with so a clean of the dizzy and some new plugs sorted that!
New Steering rack which got fitted
Also a few photos of it when I moved it on the drive.
New lights:
Bit of an update...
Taken it out quite a lot in the last couple of weeks! Been driving it every day and clocked up quite a bit of mileage considering it only gets used in the evenings
So here are a few photos of it out and about!
I also fitted some new mirrors to the speedo and new LED bulbs to give the dash a bit more light!
and fitted my headunit from the corsa to replace the pooe radio and tape player :lol:
Then today I gave it a much needed clean!
Then took it to show my dad where I recieved a large knocking coming from the rear...
I think my Dad was happy to look at something other than a Vauxhall for once. Got it on his drive and next thing I know he's got the jack out and got it up in the air!
It seems like the Outer CV or Bearing has eaten itself as it is knocking A LOT from that area. So got it back home and will be taking that all apart during the week!
Sorted the CV and bought new seats
Out with the old in with the new
A few mates and I went out last night for a bit of a drive.
We went to a tunnel in the middle of some lanes so thought it would be rude not to see what the cars sound like in one...
Mine is the second car. The first is a 328 E46 and the last a Focus ST.
Not the best update but at the start of the month I bought some mats for the car which have now arrived
and my Dad gave the leather a bit of a clean up today as he wanted to try out some Auto Glym he'd bought
Well this week end the car got a clean and clutch bled.
Yesterday we got it in the air and bled the clutch...
Unfortunately old braided hoses don't like it when you put an Easy bleed on them! The hose went pop from the master cylinder and chucked clutch fluid everywhere!
Whacked a new bit of braided line on and it was good as new
We went to brooklands and got some photos on the old bends!
Pictures aren't the best and the car is pretty dirty but better than nothing!
These were also picked up:
and then put on...
So now the car needs a little bit of lows on the front which might happen tomorrow evening...
Probably play with the rear as well but may need to work on that a bit more when I get better rear shocks.
Got a few photos yesterday whilst the weather was nice and also fitted porsche badges to the wheels
So that's it to now, got a turbo front end for it ready to be sprayed up after we do Nurburgring in August!
Thanks for reading (If you got this far )
Woops...
This came up cheap locally so snapped it up!
Wasn't planning on getting the bits soon at all but my step dad spotted it so picking it up sunday. Still got bits to sort but it won't be in until late next year when I'm happy it's exactly how I want it
UPDATE
Taken from another forum...
Well as some of you may know I went to the Nurburgring last week. We left Saturday and came back the early hours of yesterday.
The car was literally fantastic. It drove there and back and got a good pounding whilst there with no issues!
On the way we stopped off at Spa to see the GP Track and then carried on to Germany on the Sunday. We then spent the week roaming around parts of the ring, karting and generally site seeing.
Whilst at subway and karting we bumped in to OJC (Ollie) off here which was funny!
Before we left a Mate and I had decided we'd sticker some helmets up for a laugh and whack some names on the car.
Right enough talking here's a few photos of the car and some bits. (I can't be arsed to post up how many thousands of photos I have so only put a few in)
UPDATE
Finally a Car update!
As some of you may know/remember I bought a Turbo front end ages ago that I hadn't got round to fitting/spraying.
The time has finally come to get it sorted. So yesterday I set about getting the old stuff off and the new stuff on!
The photos do the talking...
New indicators front and wings.
Intercooler hole....
Redundant parts when swapping to a turbo front end!
Placed on.
Lining up
First Cut
Giving it some shape
Cut wing
The old wiring was a bit tatty as you can see so I bought some new Kit car connectors and made up a new bit of loom.
It was dark when I finished tonight but got all the lights working just need to attach the bumper properly then I can take it for paint so they can finish off the edge on the wing and obviously sort the colour out :lol:
Slowly coming along though
Should be sorting Paint over the next couple of weeks
UPDATE
I got some better photos of the interior...
Oh yeah...
Well after a week away she's back from paint!
So next task was fitting the bumper with the lights and new clear lenses
So then I went out to get some better photos with the whole car with a couple of mates.
Just need to get the back down a bit now when I get my Coilovers after Xmas.
Well I got these:
Off for powder coating with the backs in Jan
Boxing day the clutch master cylinder decided it was no more.
So bought another one which arrived yesterday:
I've also got a few extras ready to go on the car:
Quickshift Gear Linkage as my old linkage was worn
Also going to be making a rose jointed bar for the linkage arm using this track rod end from a Go Kart:
I've also had a bit of play in the steering column for a while.
The bearing I tried to get from Porsche a while back but they had discontinued it. Luckily on one of the forums I was able to get hold of one a guy hadn't fitted to his after buying it from Porsche a while back.
The white bush is for the bottom of the gear linkage so hopefully the whole mechanism will be brand new once I've sent the linkage at the bottom of the stick off to be reconditioned.
The car's off the road for the next few weeks. It's up in the air on stands at the moment. I've got the callipers off and getting the new ones powder coated over the next week.
Hopefully have the new parts on over the weekend if I can brave the rain again.
Well its that time again.
Quite a few more bits have come. Only waiting on one more bit then I can get the car road worthy again :nod:
So...
New braided lines
New discs and pads in these boxes...
New genuine Porsche calliper seals
and the best bit...
Callipers back from powder coating!
and then after some stickers...
Should have some more updates on the car after the weekend.
Now it's up to date Enjoy!
UPDATE
Well last weekend I got the old girl back on the road.
I didn't take many photos as a lot of the time I've spent working on it has been after work in the evenings.
Here's what I have done and a few photos:
I changed the lower bearing in the steering column which was a right pain in the . To do this you need remove most of the dash
I also changed the whole rear linkage setup for the gearbox for the rose jointed stuff and made an adjustable bar to replace the horrid old one.
Refurbed gear lever:
Old support bar for the linkage:
I cut down a Go Kart track rod end and re tapped the bar with the rose joints to replace the old one:
I then rebuilt the callipers:
I also got the brakes new pads and discs on.
I then took it for a drive to a mates last sunday:
It was great to drive and everything was so much more precise! Great to see my hard work had paid off :thumbs:
Today I drained the old gearbox oil and put some new stuff in.
This definitely hasn't been done since it left Porsche in 1986.
Then filled it up:
So that's where it is now. Going to roll the rear arches tomorrow and lower the back down a bit.
UPDATE
After doing some minor jobs that needed sorting I washed the car today.
Took it out for a late afternoon blast with a mate so got some photos during a stopping point.
It's booked in to a Porsche Specialist on the 27th to have the rear arches rolled so I can bring the back down with some new suspension
UPDATE
Well the coilovers arrived Thursday. After opening the box I realised there was a mix up with the rears so they've been sent back and are getting sorted free of charge thanks to the guy who's helped me get them.
Whilst still eager to see what the fronts looked like and the fact I'd sold the existing setup I began to strip it down yesterday...
We got it in my mates Garage/Massive Gazebo!
Said new front coilover
We then got the front stripped down for re-assembly
After we had the coilover in the top mount we then ran into an issue with it not mounting to the hub.
We're now waiting to contact GAZ monday to see how they suggest to sort it. So currently it's sat like this
We decided not to waste time and crack on with getting the rear torsion bar ready for the rears so after some adjustment we got some lows...
And an overall shot of my mates garden... I'm so jealous of the space he has!
*****UPDATE*****
I rang GAZ monday and they gave me the good news that the coilovers were ready!
So last night I went round to my mates where the car has been for the past month.
Instagram "I'm finished" photo
Also yesterday my rear valance arrived:
Today I spent most of the day sorting some brake ducts which were basically left over bits off of my Step dads Cobra so was a slight make it up as I go along job....
Quite well hidden, you can't see it at all when you actually look at the car.
It's not quite settled yet and we've got to play with the torsion bars on saturday so not quite the final height yet but you get the idea!
*****UPDATE*****
Came back from the 'ring yesterday after 10 days and 7 laps over there with a bunch of mates.
The car performed brilliantly and the suspension and brakes have made it 100% better than last time!
Any way a couple of photos I've found so far...
Will post more photos and videos when I get on a PC
*****UPDATE*****
So I thought I should probably update this...
I fitted a turbo rear valance just before Germany once it was painted, theres a couple of photos from Germany and also I got a 996 GT3 Cup Car steering wheel fitted in there.
I've been busy working on the trip video which will be up soon :thumbs:
...and also might have got the engine stripped down for it's rebuild... :cool:
Anyway enough of the boring stuff, here's a few photos!
So a few photos to update this:
The engine has continued being stripped and put on the stand:
That will be being stripped fully this week so next month it can be rebuilt.
I've had a knock coming from the front since I got back from Germany, it looked to be top mounts so replaced it with these that appear to get good reviews on the Porka forums:
New front tyres should be coming wednesday so I'll get them on and get the geometry checked/adjusted accordingly. Hopefully it's not thrown it out too much!
I hope it to then be ready for Combe where it'll be out on track :cool:
*****UPDATE*****
I got the engine stripped down more yesterday:
And obviously needed to show the size of the pistons by fisting it... :lol:
A few photos from going out this evening
Also the engine is coming along nicely! Its starting to go back together... I've been pretty slack on photos. I'll get some when I'm next out working on it.
*****UPDATE*****
So a bit of work and purchasing has been happening.
I got the sump off to get to the big ends and crank:
With the girdle set up these cranks don't tend to wear much. I decided I'd see if it needed a regrind.
Using a plastiguage I measured the cranks tolerance. The factory specs are between 0.038-0.07. as you can see below mine was better than that. Each one actually measured 0.025
It's safe to say only shells/bearing will get changed.
I got the engine cleaned down and painted.
I also bought 2 more goodies
Yup a new gearbox and Diff.
I bought an S2 gearbox as it has hardened gears like the turbo box but is closer ratio than the turbo so should make it a bit quicker through the gears. The standard gears feel slightly too long for track/acceleration as it's really made for autobahns.
I've now got the full rebuild kit, exhaust and various other parts I was missing so it won't be long now.
*****UPDATE*****
So the parts have been building for the engine.
I went to Trax a few weeks ago. Was a good show as always. On the drive home I found myself pulling over down a random road to lots of smoke and what I thought was going to be a fire :0
After getting it home it was clear the water pump had given up the ghost and an oil leak on the Cam housing.
Normally I'd simply replace these parts and carry on but as I knew the engine was so close I thought I'd just start getting it stripped down a bit earlier.
So got it on some ramps at my mates house and started pulling it apart the day before combe.
Gearbox out
Got all the curse word off the underneath of the bonnet
Got the gearbox back from having the LSD fitted to put some paint on it (It's a tad lairy )
The clutch on the car has never been fantastic since I've had it and it's always felt like I have driveline shunt.
I read on the internet a year ago about the rubber in the clutch giving way over the years which is why you get the driveline shunt. Lots of people carry on driving them as a clutch job is an expensive job. I was always changing the engine out so thought I'd use it until it went bang.
Well as you can see from the following photo my clutch was well and truly ruined! It's still the clutch that was fitted in 1986 as the clutch got updated to no rubber after a few years of its release.
So 2 ring trips, lots of abuse from me and 134k on the clock I don't think it did too badly...
The amazing thing being that it still has a tiny bit of meat left on it :lol:
So that's almost where it's at.
Currently waiting on a few parts then I can get the engine back together.
Hopefully won't be off the road too long, I just want to get back in it :nod:
*****UPDATE*****
So I've spent this weekend getting the engine built up so it can be moved to the car.
Not got too many photos but this weekend has consisted of lapping valves, reassembling the head, adding pistons to the block with new rings, new bearing on the crank, head gasket, head put on to the block, cam housing put on to the head and then some tarting up of parts and refitting with new gaskets.
Anyway a few photos:
Hopefully more to follow through the week.
*****UPDATE*****
So this is an update I've been waiting for.
Got the engine to my mates house where the car is:
Had a few minor hiccups involving it going in and coming straight out but now she's in to stay:
Now as some of you may know, I've had a few tricks up my sleeve regarding the setup of this engine. I've gone for a quick ratio S2 gearbox which is now full installed.
I've gone for a K26/6 hybrid turbo which will help with a super quick spool and make decent power with the perks of a smaller turbo charger.
I've also bitten the bullet and gone for a full ECU setup from Augment Automotive which are starting to make more updated, better products for these cars. This will allow me to have full logging capability, 3D mapping and able to bluetooth to my phone to use as gauges - This function won't be used on my car.
From what I've read it really is quite a bit of kit. Currently just waiting for the final bits to be sorted for it to come.
Here's a few photos Tom (the guy who runs the show) has sent me:
Old Vs New Turbo and new waste gate.
So hopefully will receive these bits this week.
*****UPDATE*****
So we've been working on the car most nights this week and all weekend.
Unfortunately we've had a lot of reworking due to not remembering which bits came off first :facepalm:
The turbo arrived so we set about getting it sorted, it got mounted up then had to be taken off and put back on due to some pipe work that had to be bolted up first.
Over the week we've got the following done:
Turbo mounted up with pipe work
Intercooler piping fitted
inlet and fuel rail etc fitted
alternator, air con pump and belts
gearbox filled with oil
manifolds and exhaust system finished
bonnet back on
badge panel back on
wiring finished apart from the turbos water pump
sorted the dash out
lots more I've forgotten about.
Any way here are a few photos, unfortunately have been pretty slack so not got any of the current state.
So that's almost where we are, looking to get some more done over the next week.
*****UPDATE*****
So the last few days have been eventful.
Got the ECU and last parts for the car Friday. Got the car all fixed up and ready to start bar fluids.
Topped it up with oil and put some water in, immediately had water pouring out the block. After a horrific amount of cursing and a very late friday night we had found the leak on the water pump due to me not getting all of the the ol gasket off the block :facepalm: :facepalm:
So got that all that back together and had it fire up yesterday... for 3 seconds. Hasn't started since but currently being helped with the mapper Tom to try and sort it out. The ECU logging shows that everything seems right that end so only time will tell. We've got spark, fuel and compression so must be a spark timing thing or overfueling I guess.
Anyway here's a few photos:
then it was like this:
Thankfully now looking more like the top photos.
*****UPDATE*****
So felt I should probably update this.
After getting it back together last friday and saturday it took its first drive saturday afternoon :cool:
Not much to report other than it was pretty fun taking it out for the first time!
So I've been desperately trying to rack up the milage to get it run in. Up to 400 miles now but half broke it today so going to fix it tomorrow and finish the 500 tomorrow.
It's going for mapping sunday then I can see what it really feels like :cool:
a few photos:
Clutch release bearing was our fault :facepalm: a slight installation error but appear to have sorted it now.
Was nice to get it home
So after driving it and gradually upping the revs it developed a bit of a boost leak.
Turns out it was from the bottom of the inlet so had to reseal that Tuesday
I drove in to work the next morning after sorting it and it scared me shitless :lol:
Boost came in hard and heavy at half throttle and got the back twitching :0 ... Yeah this is going to be a bit of a monster...
So the running in has been going well and really making me grin. Today I set off to get a boss welded in the exhaust for a lambda for sunday. On the way there a coolant hose decided it didn't want to hold water again so had to get a friend to tow me the rest of the way and home again :lol:
Got the boss welded in and will have a new hose tomorrow. Hopefully will get it ready for mapping and then I can see it's true potential!
*****UPDATE*****
So I sorted the water hose that had split and got the final 100 miles done. Did an oil change and put some proper coolant in it.
Then I got it mapped sunday. Got there with no issues. Took it for a gentle drive with Tom (the mapper) and he started ironing out the uneven bits of the map. We then got it on a long bit of private road where we were able to do it's first pull of the rev range. Immediately ran into our first issue. It was over boosting as the map was set to a 1 bar boost limit.
After upping the limit we did another run where we achieved a steady 1.2 bar of boost.... I ended up bottling the end of the pull because it was climbing rapidly in 3rd gear like it was 2nd
After a few issues like boost hoses popping off and losing alternator tension we went for a last pull.
Now we had connected the vacuum hoses properly we were now not losing any boost, achieving a lot more than both of us were expecting... This is now too much for the injectors. We've maxed out the injectors for a full rev range at 0.8 bar of boost - it starts to run lean on more boost.
Tom had a look online and people are claiming the standard injectors are good for 270WHP but we're not sure it's quite making that power.
So now we've left it on a safe map at 0.8 bar with the intention of upping it after xmas with new injectors and a lambda sensor which should see it making some really good power.
Delivery is pretty good at the moment but the trouble is I know what it's capable of now...
So got it home after a few issues and then I broke it right outside my house :facepalm: It's managed to loosen the power steering pump bolts and shims which have fallen off. So now got new ones on order from Porsche. Hopefully should be here in the week.
I'll get videos on the weekend :thumbs:
*****UPDATE*****
So after the last update we had a few issues.
We took it out and broke it, the wastegate had worked itself loose. We'd also noticed it was also blowing from the turbo... Great.
This meant taking off all the ancillaries to get the turbo off to change the gasket/work out why it was blowing.
Whilst dismantling it we'd found a few bolts also loose. After a long think we decided to check the timing of the balance shaft belts as we were thinking it may be rattling itself loose.
After discovering that the balance shaft belt had worked itself slack and had moved timing we were sure this was causing our issues.
After a few nights work we had it running again. It was running sooo much smoother. Since then I've been just giving it a bit of curse word and it seems to be taking it quite well. I had a problem with the starter motor but that appears to have been sorted now as we had discovered a leaky slave which was leaking on to it.
So sorted the slave and have just been driving it to see how it lasts.
I've now got an issue with a CV joint but that's kind of expected seeing as it was probably the original one on the car....
Anyway enough text. Here's a quick video of it.
We hooked a mic to the outside of the car and used the onboard sound as well.
I hope that has made some vague sense…
Any comments are welcome!