Pelican Parts Forums

Pelican Parts Forums (http://forums.pelicanparts.com/)
-   911 Engine Rebuilding Forum (http://forums.pelicanparts.com/911-engine-rebuilding-forum/)
-   -   964 3.3 Turbo EFI Conversion using Syvecs (Life Racing) Engine Management (http://forums.pelicanparts.com/911-engine-rebuilding-forum/626572-964-3-3-turbo-efi-conversion-using-syvecs-life-racing-engine-management.html)

Spenny_b 08-26-2015 11:53 PM

Hi Jeff, yes, that's probably the model GA-184A, which would've been more than adequate and would've meant I wouldn't need to buy a set of adapters (more tools...yay!)

Mind you, with the larger item, at least I can justify now getting into Tanks.... ;)

Good to know they work - Agree, it's going to be a rare case of using them, but Phase 2 of the car project (assuming I don't sell the bloody thing in frustration - aka last night - doesn't happen first) is a complete suspension overhaul; front suspension will be coming apart again, as well as inspecting and maybe rebuilding the rear driveshafts, so there's a few more uses for it in the immediate future.

Cheers

Spenny_b 08-27-2015 01:57 PM

Todays update....

The postman arrived today while I was in London, with a couple of the new toys....Brake pressure bleeder:

http://img.photobucket.com/albums/v2...A25D07EAD5.jpg

And the set of adapters I'm going to need for the torque multiplier. These are impact adapters, so I'm hoping that they wont shear when used....I'd like to think that any 3/4 > 1" drive adapter could take a measly 360lb/ft! :p

http://img.photobucket.com/albums/v2...79FE9F145A.jpg

Intercooler is back in place; the way I eventually did it was to remove all other fixings (i.e., the front bolt and the coupling on the hot charge pipe), undo and remove the bolts holding the cold pipe to the throttle body, then wrestle the cold pipe into place, install the locking band, then reinstall everything else. I'm now not convinced that I've done an adequate job on the hot pipe either, specifically the join from the turbo outlet to the pipe itself, which uses a short silicon joiner hose. The problem seems to be that when nipping up the Mikalor clamp onto the hot pipe, there isn't quite enough straight section for a really nice tight seal, instead it pops out very easily. Now, being installed under the billet inlet tank, it can't actually go anywhere but that doesn't ensure that the joint is going to hold the pressure.

So....my plan at the moment is to buy a straight reduction silicon hose, cut off the tapered ally section that interfaces the turbo outlet to the pipe, swage the remaining 3" diameter pipe and use the silicon hose to mate the turbo to the 3" directly. They're 125mm long, so plenty of scope for adjustment and it also means the top Mikalor clamp will be higher and more accessible.

Finished installing the bumper. Then found, laying on the side, a pair of nicely powder coated ribs sections that are used to sandwich the plastic and spread the tension. For GODS SAKE!!! Off come the heatshields and out come those screws. Again.

Lost the will on that part tonight, so I resumed the cabin switchgear installation again, made up some M5 grub screws and got everything absolutely spot-on.

http://img.photobucket.com/albums/v2...40B2502F8F.jpg

http://img.photobucket.com/albums/v2...449707F839.jpg

The boost control, with 3 settings, aligns perfectly in each setting with the 3x legends on the panel. The traction control will (probably) have 8x settings, but of course, with only 3x legends on that switch as well, it's going to look a little weird. I'll need to decide with the centre vertical setting is max TC (which probably makes sense aesthetically), or whether to set Setting #1 at the LH 7 o'clock legend, then rotating clockwise. Anyway, detail, and functionally it's another success. A 964 Turbo with a Carrera 4 switch panel....that should stump a few unsuspecting "anoraks". ;)

Finally this evening, after a few phonecalls to try and source the correct fittings to assemble a remote bleeding hose for the clutch slave cylinder, it looks like there's no off-the-shelf M6x1.0 > -3AN (3/8" x24 UNF) adapter. It's possibly achievable by using some mountainbike brake parts; they use M6 banjo bolts but only onto -2AN hose. Remote bleed nipples are only -3, so it gets a little clunky/messy.

So...have lathe....have stainless hex stock....have dimensions....time to get making!

I may well make 2x different adapters; the first will use a 45º seat per the original bleed nipple, which will then seal against the internal face inside the M6 bleed outlet. With a 2/2.5mm hole drilled through the middle, it should still leave enough seating material. Plan B will be to make a second adapter that seals with a copper or aluminium washer against the back of the slave. From memory it looks to be a machined but painted finish; whether the face is perpendicular enough to the hole to ensure a seal, I don't know, hence why it's my second option.

The M6 end will have the 45º seat as mentioned; the male -3AN end is simply a 3/8" x24 UNF thread with a 37º seat angle.

Then, onto the adapter will fit a simple -3AN 90º swivel joint, 0.5m of teflon hose, then a male -3 bulkhead/bleed nipple adapter. This will probably then go onto a bracket that in turn mounts onto a spare M8 stud on the diff plate of the gearbox (which will then be shielded by the gearbox cover)

That's it for this evening....not sure how much will get done this weekend, lots of plans with Lucy, but we'll see if I can sneak an hour or two...

304065 08-30-2015 05:01 PM

Now THAT is cool. . . externally everything Porsche. . . not that you would ever valet park it, but it provides you a stealth way to turn the boost down. . . and the traction control up. . . or will you erase the silkscreen and come up with a decal of a turbine blade. . . and the traction control image with the squiggles. . .

The remote bleed setup is interesting. . . can you sketch it on a napkin and shoot with phone cam?

Spenny_b 08-30-2015 05:44 PM

Quote:

Originally Posted by 304065 (Post 8774325)
Now THAT is cool. . . externally everything Porsche. . . not that you would ever valet park it, but it provides you a stealth way to turn the boost down. . . and the traction control up. . . or will you erase the silkscreen and come up with a decal of a turbine blade. . . and the traction control image with the squiggles. . .

No, I'm probably going to leave the legends as-is John. Like the stock look, with the rear end of the car meaning boost rather than wing lift, and the 4wd legend referring to TC....kind of logical. Steve and I were speaking a few weeks ago about how to put in a hidden, key operated setting into the map that both keeps the boost control valve active all the time (open wastegates) and physically limits the eGas opening, so that it really is a valet parking mode.

Quote:

The remote bleed setup is interesting. . . can you sketch it on a napkin and shoot with phone cam?
Hopefully I'll have it made tomorrow evening, but really easy, M6/-3 male/male adapter in the slave cylinder (replacing stock bleed nipple) > 90deg fitting > -3 hose > -3 bleed nipple bulkhead fitting.

http://img.photobucket.com/albums/v2...5DF841181B.jpg

Just need to find a mounting location that's higher than the slave cylinder.

Spenny_b 09-01-2015 02:57 PM

Bloody marvellous day!

First off, my new Snap-On tools arrived, and I have to say, chuffed to bits. Thanks to Matt, the chap who I bought them off; he said they were mint and he's absolutely on the money, unmarked and if they've been used then I can't tell.

My God they're massive. If your name happens to be Mr I. K. Brunel, then please do give me a shout, I can lend you the tool for the next bridge you have in mind.

I need Snap-On tools in my life. Therefore a toolbox makeover...my kit is nice, falls in the "enthusiastic amateur" category (Halford Professional is actually made by Britool, so pretty decent stuff) but this is another level and of course, guaranteed for life....so if my numbers come in, it's not the dream car (kinda got that), it'll be the like-for-like replacement for Snap-On. Oh and something with a V8....I need a V8. A manual 928GTS will do nicely. Thanks.

Anyway, a quick call to my Brother to come and sit in the drivers seat and stamp on the brake pedal - where he then spent the next 10 minutes in shock about how much smaller/closer everything is in a 964 than his 997. Some care to get anything that could be damaged out of the way (should something let-go), and within a minute, the LHS nut was undone....rare that I'm easily impressed, but I was laughing at how much of a doddle that job had just become. Another task that I'd been mulling over and sweating a little, and it's now sorted.

http://img.photobucket.com/albums/v2...B53077E872.jpg

http://img.photobucket.com/albums/v2...5F0663A59E.jpg

Didn't remove the nut, in fact, nipped it back up to ensure nothing daft happens when lowering it off the jack. At the moment the car is pushed over to the far side of the garage so I can get in and out for interior work, but when I'm ready the car will be centralised and up on the vehicle lift, ready to install the traction control components onto the hubs.

Yesterday I started to make the M6 > -3AN adapter for the clutch, but was thwarted by the lathes coolant pump playing-up. With some desperate attempts to get it working again (I'm making it from stainless), I managed to pull off the pressure hose. Inside the suds tank. At the back. Completely unreachable......Grrrreat.

So, in addition to the hub nut, Ollie also helped shuffle the best part of a tonne of lathe out from its resting place. A couple of hours later and it's all stripped, cleaned and reassembled, fresh hose clamps, new elbow, new clips....done properly this time. Turned out that the culprit was a sticking ball valve in the tap head; I now have more flow than I would ever need, but it's too late in the evening to continue the turning, so that'll get finished tomorrow. Hopefully the remote hose can then be installed, ready for the clutch to be bled.

Brian popped over earlier to hear the car fire-up, and also to drop over a new ashtray housing for the dash, and he's found me a loom clip for the front bumper beam! That got fitted immediately before I manage lose it, I only now need to cut a couple of lengths of the single ply silicon ducting hose and push them onto the ducts, then the bumper can go back onto the car permanently.

Back tomorrow...

Spenny_b 09-02-2015 02:03 PM

Evening folks, very short update tonight....

Back onto the lathe, eager to get that adapter finished. All very straightforward, and it came out rather well....pleased with the result, although almost did fall foul of not reducing the lead-in diameter of the -3 (3/8") thread down to the thread core...this would've prevented the 37º seat angle from engaging, a potentially messy problem.

http://img.photobucket.com/albums/v2...32BF0946A9.jpg

So, once it was taken care of, a trial fit and it's another job off the list. Time to install it into the slave cylinder - although not tonight, been a long day, and another very early start tomorrow.

http://img.photobucket.com/albums/v2...C6A4A39E8F.jpg

304065 09-02-2015 03:31 PM

Hold it a minute, that thing is bloody gorgeous!

What did you do, make it out of hex bar stock, turn the ends down then thread them?

No wonder the Industrial Revolution started in Britain!

(Although Ol' Isambard would have made it 24' across, out of cast iron, and used it as part of the London water system :))

Spenny_b 09-03-2015 01:19 PM

Lol! You sound surprised mate?! :) Thank you. It's not perfect, the drill bit I grabbed that looked "ok" was actually a little large, it hasn't left much of a 45º seat at the M6 end to seal with. If it doesn't seal, then I'll simply part it off and use an ally washer to seal the mating face of the hex section against the slave cylinder.

In terms of making it, yup exactly, I had a length of stainless hex-stock 13mm AF, perfect for this. Could've probably got away with making it out of ally hex as well, but was a little concerned that the M6 end would be a little fragile and easily sheared with too much enthusiasm when tightening (or vibration with the car in use).

Going to save this job for the weekend; meeting up with a pal tomorrow night for beers in London, then on Sunday up to Santa Pod for the FIA Euro Drag finals...weather permitting...doesn't seem like a year ago when I bought that piston & rod that I photo'd earlier in the build.

Spenny_b 09-07-2015 07:04 AM

Post weekend update.....

Got some good work done over the weekend; the Santa Pod plan (drag racing) didn't happen, for reasons very boring, but that then freed up yesterday to have a really good crack at reducing the To Do list.

First off, the fire extinguisher. I finally got sick of mentioning it and seeing it as the perennial item-that-never-gets-done on my whiteboard, so time to finally get the bottle mounted in the cabin. To do this, I made an ally template with the same mounting hole pattern as the bottle cradle, and one some guide markings were made with masking tape, time to use this as a drilling plate. I managed to get the bottle really tightly mounted up under the lower dash, and partially hidden under the footwell hot-air duct from the HVAC system.

Not quite tightened up, but approximately in place...

http://img.photobucket.com/albums/v2...B5022F270E.jpg

http://img.photobucket.com/albums/v2...5230AA8A3E.jpg

Not a particularly easy job, as trying to drill the holes right up high is a little tricky, then dealing with the pretty thick (and super sticky) sound deadening just meant that checking a few times was the order of the day. The metal in the footwell is a double skinned affair, so I had to use M6 Nutserts to secure the bottle.

http://img.photobucket.com/albums/v2...7D8AACC5DA.jpg

Next job was to then mount the control unit for the extinguisher, somewhere discreet yet accessible. The glovebox was a good candidate, and it fitted really nicely down the LH side. Lifeline supply the unit with the same double-sided tape as used on rear view mirrors - clearly not very useful for sticking onto the flock material, and it didn't quite fit well enough to stick against the sidewall anyway, so a section of U channel ally was used to interface the two.

http://img.photobucket.com/albums/v2...E93006A073.jpg

The DIN plug for the control box was then held really snugly by the depth of the glovebox, drilling a 5.5mm hole just large enough for the cable to exit, but small enough to stop the connector boot from passing through, thus keeping it all securely plugged into place.

http://img.photobucket.com/albums/v2...5C34F62F28.jpg

http://img.photobucket.com/albums/v2...3B47F8AA29.jpg

I have 2x waterproof red buttons that came with the kit, both have got a really nice red anodized shroud to prevent accidental activation. I'm not using the second switch (usually mounted externally for race marshals to use), so have re-used that shroud to mount over the small toggle switch on the control box....hopefully preventing accidental arming if something in the glovebox moves in transit.

The traction control/boost control panel is now also in place, the auxiliary harness neatly routed under the passenger footwell sound deadening.

Next job on this will be to mount the Big Red Button somewhere in the cabin, then to wire the 3 items together. Finally, the 8mm tubing will be passed down the tunnel, but this was best left until I could get under the car.

A quick cuppa, then time to finish the ducts on the front bumper. All now sorted out, mounted securely, and doing exactly what I need of them. Bumper yet to be screwed back onto the chassis; I need to hook-up the headlight squirters first.

http://img.photobucket.com/albums/v2...43EC8E13BF.jpg

Next up, another borrowing of my Brother so that we could loosen the RHS front hub nut, before hoisting the car back up onto the vehicle lift. This side did prove to be a fair bit more reluctant, but eventually it relented! A quick lit of undoing and re-tightening before then getting the car airborne.

Final job of the day was the clutch slave cylinder and its new remote bleed hose. First issue was that my guesstimate of how long to make the M6 section was somewhat "off". This is the bleed nipple replacement, but I made it too short, so the hex section was bottoming out before the 45º seat had engaged. Easily fixed by spinning it up in the lathe and reducing the width of the 13mm AF hex section - it was way over the top anyway.....6mm reduction to OD for M6, then an some more thread cutting, followed by a small undercut to M6 core diameter. Perfect, nips up snug with about 2-3mm showing.

http://img.photobucket.com/albums/v2...68E93F58E2.jpg

The 1m of -3AN hose looks to have been an inspired decision (!). Of course, the deliberate mistake I posted last week re mounting the remote nipple in the footwell was of course utter nonsense...that wouldn't have been higher than the slave cylinder, so potential air trap. The 1m of hose did allow me to route into the engine bay (despite me saying I didn't want any clutter...). There's a nice gap in the tinware near to the auxiliary oil pump, where it then runs behind the AC lines, up the bulkhead and secured under the parcel shelf using a P-clip and plastic nut onto an existing sound-pad stud.

http://img.photobucket.com/albums/v2...29C7ED6D45.jpg

Final job last night was to make a bracket to mount the bleed nipple just above the IC on the left hand side. Not quite finished yet, and I may well re-make it to be a little smaller. It'll be anodized when finished either way....but now I can crack on with actually replacing the brake fluid and trying my hand at the clutch system. Hopefully tonight.

http://img.photobucket.com/albums/v2...72738337AE.jpg

Spenny_b 09-07-2015 03:15 PM

Well, not quite the evenings work I was planning on!

I got started this evening on continuing the work on the remote slave cylinder bleed hose; trimming the mounting bracket and changing the mounting onto the chassis (I want to get it mounting under the sound pad rather than on top of it - nips up tighter to the chassis and aesthetically it looks better)....all in anticipation of finishing the brake and clutch bleeding tonight.

Next job, to tighten the 90º coupling onto the adapter I made. Not easy getting 2x spanners in there to counter hold it, and sods law, what I thought was a tight enough "nip" of the adapter last night, wasn't. The whole lot came loose, but with the 90º coupling now tight onto the adapter, with the elbow in the wrong orientation. Grrrr. An at this point I'm wondering whether I've (yet again) gone overboard with a solution for an answer that wasn't *really* there....certainly for the few times I'll hopefully ever need to bleed the clutch. So potentially a good $100 wasted on parts, and was just about to have a right old swear but instead decided to leave the clutch until tomorrow and get on with the front hub bolts - I don't have any bleed hose to hand anyway, so running fluid tonight was a non-starter.

And then the evening went stellar!

All 4 wheels off (ready for brake bleeding, refitting of inner arches, final bolt-up of the bumpers), and the RHS hub undone...all very easy, bolt out followed by the ABS timing wheel assembly. A cinch, just a gentle tap with a deep reach socket through from the front.

http://img.photobucket.com/albums/v2...t/IMG_7485.jpg

You may remember that I had two different timing wheels water-jet cut, some months ago. Both are similar, just one was slightly larger than the other, and as I type this, I may well also try the larger of the two when I resume play tomorrow night.

Anyway, careful mark-up of the mounting holes for the timing wheels, hoping and praying that the material wasn't hardened, otherwise game over, and think of a Plan B.

Thankfully, the pilot holes went in beautifully, and certainly very glad I took the time to remove and drill them securely on the pillar drill; definitely not a job to be done in-situ (although it did occur to me instead of buying the torque multiplier!)

http://img.photobucket.com/albums/v2...t/IMG_7482.jpg

Holes drilled again and tapped to M3, then the plastic insulator rings were tidied up (they were straight from the water jet cutting process, and a little scruffy). These are being used so that my hall effect sensors don't pick up any of the ABS teeth, and vice-versa with the ABS sensors picking up the metal timing wheel I'm mounting for traction control.

http://img.photobucket.com/albums/v2...t/IMG_7483.jpg

Finally, the holes on the timing wheel needed to be countersunk. If I were to remake these wheels, then I'd make 2 changes; firstly, extend the land around the outside of the 4 holes (similar but inverse to the wheels mounted on the gearbox output flanges), and I'd make them out of thicker gauge material; there's not really enough meat there to countersink the holes for M3, but they do need to be as flush as possible to clear the HE sensor....I predict some very fine shims will be needed to mount the sensors at precisely the correct distance from the wheels.

http://img.photobucket.com/albums/v2...t/IMG_7484.jpg

At this point, I had one of those "Oh CRAP" moments, whereby I thought that the ID of this assembly hadn't been considered at all, and wondered whether I could then get a 32mm socket in there to tighten up this M22 bolt!

First try using an impact socket - nope....uh oh.

The second socket, non impact style, thankfully cleared perfectly. I'd like to say it was well-engineered, but it was purely luck!

http://img.photobucket.com/albums/v2...t/IMG_7486.jpg

Last job for the evening was to trial fit everything into the upright, including the ally top-hat caps that I made last year. These will be used to both seal the hub (replacing the plastic caps) and to mount the HE sensors axially. It looks like these may need to be spun up on the lathe to reduce the wall thickness, and/or the OD of the plastic insulator ring may need reducing, as they don't *quite* fit as originally intended. Small challenge, no biggy.

So, overall, very pleased that another perennial to-do item is underway and going as planned...with things going this well, the car will EASILY be finished this decade.

304065 09-07-2015 05:58 PM

Bah! Even an oversize socket is no match for a man with a lathe! :)

Spenny_b 09-08-2015 05:55 AM

Quote:

Originally Posted by 304065 (Post 8785125)
Bah! Even an oversize socket is no match for a man with a lathe! :)

Thankfully it was a match that didn't need playing, John!....the snuggest of fits [/fluke]

Spenny_b 09-08-2015 06:10 AM

In a bid to step away from the monitor at lunch, I was eager to see whether the other set of timing wheels would be a better option than the set I used last night....and they are. Half an hour spent in the workshop (who needs food anyway), and everything is A-OK....

The other set of timing wheels are a fair bit larger in OD, therefore more material on the edge of the 3mm mounting holes, and so they havent broken through with the countersinking. In drilling the countersinks, because the material is pretty thin it naturally does "push" material through to the back, making a dimple. Rather than remove this and open up the hole diameter to 4-4.5mm, I've left them, then also countersunk the plastic ring that sits underneath. If nothing else, it helps keep everything located concentrically.

The plastic rings were mounted onto the 3-jaw on the ID, and the OD reduced by about 2mm until they were the exact diameter as the OD of the ABS timing wheels themselves.

When all mounted back together, the countersunk screws sit really nice and flush now, a lot better than last nights experiment.

http://img.photobucket.com/albums/v2...F96B49FEEB.jpg

http://img.photobucket.com/albums/v2...366DD4D564.jpg

Trying them back on the chassis and it fits like a glove! The ally top-hat's slip in beautifully, and giving the wheel a spin results in no witness marks on the inside of he caps. Excellent! Not bad for 30mins work.

http://img.photobucket.com/albums/v2...4790F30E54.jpg

http://img.photobucket.com/albums/v2...91A5CD6429.jpg

Tonights job, with a mug o'tea and peace and quiet, will be to calculate the offset for the HE sensors to be mounted, and then mount them into the 4-jaw so that the holes can be bored.

Spenny_b 09-08-2015 02:38 PM

Another productive evening, and for the most part, everything went swimmingly.

So, first job was to replicate the RHS timing wheel mounting on the LHS wheel...when you know the exact procedure, everything is so much quicker; I had the hub bolt out, the wheel off, drilled and mounted inside 20mins.

Next job was then to measure and calculate the position of the HE sensor relative to the centre-line of the timing teeth. I decided on positioning it 90º from the ABS sensor; no particular reason, just looked best there and about as out-of-the-way from adjacent suspension fixings as possible...a whiteboard full of sketches and calculations later, and the top-hats were marked up and ready for pilot drilling.

http://img.photobucket.com/albums/v2...5CB4E2469D.jpg

Now, the plan was to mount these into the 4-jaw chuck on the lathe, however, the hole to be bored was so offset that the piece couldn't be held satisfactorily with all 4 jaws. Simply not safe, and way to easy to damage the cap itself (best case).

So, back onto the pillar drill, and drill out the hole to the biggest twist drill I have, 13mm. Tomorrow I'll need to nip out to the local tool shop and buy a step-drill. Don't know why I haven't bought one before, but there you go.

As you can see on the RHS cap in the picture, when placed over one of the timing wheels, the teeth will be in perfect alignment with the centre-pip of the HE sensor. All that needs to be done is make some spacer rings to set the height correctly once installed.

http://img.photobucket.com/albums/v2...00D5037DAD.jpg

The final job for the evening, whilst riding the crest of the Garage Gods good-fortune wave, was to drill the hub uprights in order to use an M5 fixing that will retain the caps/sensor inside the hub. The original black plastic caps simply snap into place in much the same way as wheel centre caps, using 4x fingers to lock into an inner groove detail. Clearly, can't use that with this cap, so the plan was to drill and tap a hole that will lock the cap into place....

http://img.photobucket.com/albums/v2...6A18475640.jpg

Next step, insert the cap back into position, then drill and tap the M5 thread. Now, my thinking was to tap right the way through in one go, so no risk of misaligned thread ending/starting positions between the hub and the cap. Good plan, except that about 10mm into the thread cut, the bloody tap snapped. Clean off. DAMMIT! My luck had run out, clearly.

Desperately trying not to panic (or swear very loudly), the next hour was spent trying every tool in the box and trick in the book to try and unwind it. Fat chance, no way it was coming out that easily. Now, at this point I started to panic a little; the cap was installed and what I guess was the tip of the tap was preventing it coming out again. It couldn't have been much, there was a lot of play...so, time to bring out the reverse slide hammer, and thankfully the 13mm hole that had been drilled moments before allowed the use of a 90º hook to be used to tap it out backwards.

The remnants of the tap did eventually come out - what worked for me was to hammer in a fine tapered punch down the exposed ends of the 3 flutes; although hardened, the tap didn't like the compression force, and so I shattered it out. Phew!

Change of plan, the hole in the hub was now going to be a 5mm clearance hole! No harm done, but I now need to add an M5 tap to the tool shopping list tomorrow, although I did manage to grind remaining part of the tap into something usable, which served well to tap the hole in the cap....

http://img.photobucket.com/albums/v2...77D9F888B9.jpg

(Hate posting pictures of the suspension looking so scabby - but as mentioned a few times in this write-up, suspension refresh and upgrade is Phase 2)

Again, repeating the procedure on the LHS was a piece of cake, and apart from painting a thin coat of the Dinitrol wax coating onto the timing wheels (I had to breach the electroplating to cut the countersunk holes), that's where I've left it for the evening. Very productive, and apart from getting the top hat caps black anodized, I reckon this job will be completed tomorrow night.

Spenny_b 09-09-2015 03:06 PM

Quick update....

Managed to get an 18mm twist drill from the local tool shop; the planned step-drill option wouldn't have worked as the material I was drilling out to 18mm was too thick for each of the steps on the tool.

Mounting the caps firmly onto the table of the pillar drill using a couple of finger clamps meant that I got a perfect cut each time, giving a 0.1mm clearance fit to the sensors 17.9mm OD. Fastening bolt hole positions then marked, drilled and tapped to M6....

http://img.photobucket.com/albums/v2...CBF9F92DC2.jpg

http://img.photobucket.com/albums/v2...9647F27EEA.jpg

http://img.photobucket.com/albums/v2...02C21B6D0A.jpg

...and the sensors mount perfectly. Next job was to then measure the dimensions for the sensor stand-off collars that will set the sensor 1.5mm away from the timing wheels. At this point, I confess to getting distracted by Apples announcement (sorry, am an Apple fanboy), and so by the time I finished watching it, not live, it was too late to make the collars. Anyway, they're all now drawn up on the whiteboard and the stock material is ready to go, so perhaps an early night/early start to get them made before the day-job starts.

The intention is to machine a couple of recesses into the ID of each end of the large collars, which will then accommodate an o-ring top and bottom, in an attempt to prevent as much moisture/muck ingress as possible into the centre of the hub via the clearance hole for the sensor body.

I also bought an M5 time-sert kit today. My thinking for this is to use time-serts for the M5 cap fixing holes that are used to retain the caps into the hubs. Thinking a few years down the line, if that M5 screw ever seizes into the cap, it's going to be a right pain in the arse to get it out, not to mention a destructive exercise. Using a stainless threaded insert should help to prevent this, albeit I'll need to Dremel each insert a little shorter to cater for the wall thickness of the caps.

boosted79 09-10-2015 05:21 AM

Nice work as usual. It looks like they use as much road salt there as they do around here, it makes a mess of a car's undercarriage after a few years. It makes the car makers and the body shops happy though. :D

Spenny_b 09-10-2015 09:38 AM

Quote:

Originally Posted by boosted79 (Post 8788394)
Nice work as usual. It looks like they use as much road salt there as they do around here, it makes a mess of a car's undercarriage after a few years. It makes the car makers and the body shops happy though. :D

Yes, you're not wrong mate, "we" use salt like it's going out of fashion in the UK. Except we're absolutely rubbish at planning and using it when it's needed - it always makes the headlines when "oh dear me, look at that, we've been hit by an unexpected blizzard" followed by "...and we couldn't: get the salt/spread the salt/wake the salt spread bloke up in time" (delete as appropriate)

Not sure what you guys do over there in terms of road tax, but we have either an annual plan or a 6 month option over here; most folk with toys put them to bed over the winter and save about half the cost of the road tax each year, and not expose them to the road salt.

Spenny_b 09-10-2015 09:47 AM

Some time spent on the lathe at lunch meant that I've now finished the front traction control setup! Hurrah!

As mentioned in last nights update, the measurements and drawings were all done in preparation, so some quick turning got the final 4 pieces made.

http://img.photobucket.com/albums/v2...FF62BF8266.jpg

The stand-off for the main body of the sensor has a relief at each end to accommodate an o-ring, nothing too tight, but a nice light seal that will keep out any spray...

http://img.photobucket.com/albums/v2...7194F30C95.jpg

Finally, the box of 500 assorted o-rings I bought a few years ago has paid off!

Once mounted onto the front uprights it all looks exactly as I was hoping; nothing fouls, the only thing I've not yet checked is the electrical signal. The HE sensors aren't yet terminated with the Sureseal connectors, I'll need to take them back over to Simon @ Sileck to get them fitted, but I reckon I'll have about a week before the electroplating shop can get them anodised, once they have them.

http://img.photobucket.com/albums/v2...656E8D5ABE.jpg

Tonights job - brake fluid change and clutch bleeding (yes, really this time. Promise)

Spenny_b 09-10-2015 04:30 PM

Great progress this evening....finally, the clutch and brakes are bled.

First job, as it was an empty fluid circuit, was to bleed the clutch. I was dreading this a little, as Chris had said that it can often be an absolute swine to get done, but when we were on FaceTime a few weeks ago, and he saw the far simpler pipe run for RHD cars, we both thought it was perhaps the convoluted run across from the LHS, traversing the tunnel and then going rearward, that maybe becomes an air trap.

Sorry Chris, you're gonna hate me for this....but it all went very smoothly! The Sealey pressure bleeder has been superb this evening. Really nicely made piece of kit, feels extremely robust - to anyone thinking of buying it, do it...wish I had years ago. I left the clutch line open and flowing for 3-4 minutes, getting well over a litre purged. I got to about 2mins, thought it was done, no bubbles for a minute or so, then all of a sudden a loud splutter followed by the purged air escaping. Another minute and I shut it off. No need for the remote bleed pipe I blew $100 on. Dammit. Oh well, I'm sure I'll use the fittings somewhere in future....K.I.S.S. (Keep It Simple Spencer)

Sitting in the cabin to try the pedal, and it feels great. Again, Chris and I had discussed the use of the 997GT2RS clutch assembly and how heavy it was likely to be. Sure, it's heavy but initial thoughts are that it's certainly not unmanageable. It feels like it's actuating rather than compressing air, but of course I won't know until I go to move the car under it's own steam. Fingers crossed.

So, something I hadn't reckoned on doing was purging/bleeding the hydraulic pump unit, to rid it of the old fluid. The 964 Carrera's are vacuum brake assist, the 964 C4 and Turbo's both use a hydraulic boost system. Thankfully it's only the C4's that need the Bosch "Hammer" diag tool to cycle the traction control locking circuit. Following the procedure in Adrian Streathers book, it all looks to have gone fine....I got a froth of bubbles to start with under pump pressure, and as documented, they then subside. Switch off the pump, bleed pressure off again, then cycle the pump a second time...repeat as necessary until no more bubbles. Which I did manage to do (I think) before the battery started dying. Again, crossed fingers.

Finally onto the callipers. This was an absolute doddle - I was done in 15minutes. No seized nipples (we free'd them up and changed the fluid when I first bought the car, so they shouldn't have been seized, but you can never tell...). A 2litre bottle (plus a slick of overflow on the garage floor) is now full of dark horrid brake fluid. Job done!

Spenny_b 09-10-2015 04:38 PM

So, something I'm not too happy about....

A few months ago, in anticipation of removing the front hub spindles, I bought a pair of replacement M22 nuts; as they're a prevailing torque design, they're a once-only use item.

This evening, I just happened to be tidying up, and had the old and new nuts side-by-side.

http://img.photobucket.com/albums/v2...174EE6F9C6.jpg

It's definitely the correct part, per the PET it's illustration 401-05, Item#16, 999 090 008 02...but it's way shorter than the one's that have come off.

Anyone have any thoughts? I'll post the Q over in the 964/993 forum too, and hope that Bill Verburg sees it and comments.

Spenny_b 09-15-2015 03:19 PM

Not too much progress over the weekend, busy doing other things, but here's what's happened since the last update.

First off, the query about the different nuts has been put to rest. A couple of folk over on the 964/993 forum confirmed that they have the same nuts as the new ones I have...a chat with Bill Verburg also confirmed that he's running the slimmer items on his car (thanks Bill).

The rear nuts on the end of the driveshafts are the same as the old ones I've just removed, but upon speaking to the guys at my OPC, they confirmed that none of the superceded part numbers for the front nuts have ever included the p/n of the rear nuts; they've never been the same item.

So, it looks like somebody in the cars previous life has grabbed a pair of nuts off of the rear of another car and fitted them to the front of "my" car. Also, the threads were coated with copperslip. The Porsche workshop manual calls for the use of Optimoly HT which is aluminium in colour and to my knowledge, Porsche have never used copperslip on the 964. Bit of a giveaway that it's been apart before (thanks for the info on the Optimoly HT, John; a long historic reply of yours that I Googled earlier!). If you notice in the previous side-by-side pic, there are witness marks on the left of each face on the hex...which look suspiciously like impact/hammer gun markings.

So, mind was at rest to go ahead and fit the nuts I had; the p/n was again confirmed by the OPC that it is the latest revision.

My mate Ian very kindly borrowed the biggest torque wrench I've eve seen from his work - a Dunlop item and regularly calibrated.

http://img.photobucket.com/albums/v2...792A9A4AAF.jpg

http://img.photobucket.com/albums/v2...BBF6DDF251.jpg

Threads lightly coated, along with the flanged faces of the nut, and it was a doddle to re-torque everything....me on the end of the 3ft breaker, him on the wrench.

Nothing remarkable about a picture of a nut, only that it may help somebody in the future with a similar question as I had...

http://img.photobucket.com/albums/v2...E93D6C9011.jpg

I now have the hall effect (HE) sensors back from Simon, who's done a great job of re-terminating them with the correct Sureseal plugs to interface with the ECU loom. Proper job, double sleeved with Raychem DT25 for robustness and resin bonded ends to seal everything.

http://img.photobucket.com/albums/v2...83D429C1F2.jpg

Finally this evening, I finished the wastegate screamer pipes, cutting them down to the length I want. Long enough to ensure that the hot gases/flames don't damage anything, but short enough to maintain ground clearance....

http://img.photobucket.com/albums/v2...52779CE947.jpg

http://img.photobucket.com/albums/v2...D4CB5A6302.jpg

Pat RUFBTR 09-18-2015 10:58 AM

Hi Spencer!

Great the pipes of waste-gate! ;-)

Spenny_b 09-18-2015 03:16 PM

Hi Pat, cheers mate!

Spenny_b 09-18-2015 03:37 PM

Tonights end-of-week progress report....

The hot-side silicon hose arrived during the week, a step-down (or step-up...) straight coupling from 63mm > 76mm and 125mm long.

Next job was to cut the pipe down a little, from this...

http://img.photobucket.com/albums/v2...63ABF4AFE4.jpg

To this, with the raw end swaged. Tape is just marking the top of the new hose with it set at it's max lowest position on the compressor outlet....

http://img.photobucket.com/albums/v2...E5B95F1B34.jpg

And then time to get it into place, set the height correctly, and it's another job finished. The Mikalor clamps are a lot easier to get to now (most of the issue was the reworking of the rear tinware, which severely limited the orientation and access of the clamps), so mission accomplished with nice tight clamping at both ends.

http://img.photobucket.com/albums/v2...78E2223C43.jpg

Spenny_b 09-18-2015 03:42 PM

Onto the traction control tasks, the caps and sensor stand-offs were plated during the week - another quick drive down the road to collect them....another great job by Butterworths (Regia) Ltd....

http://img.photobucket.com/albums/v2...97EF92E560.jpg

First job was to install some timeserts into the M5 retaining holes. As stock, they're too long for the wall thickness of the caps, and would foul the ABS timing wheel immediately behind the cap. So, a piece of scrap ally of the same thickness, drill & tap the timesert hole and insert the timesert into it....remove the majority of the excess with side cutters, then grind them flat on the offhand grinder.

http://img.photobucket.com/albums/v2...BC5F088DB3.jpg

http://img.photobucket.com/albums/v2...20326899EA.jpg

Then it's just a case of carefully removing them (at this point they're only 3mm thick, so a little fragile) and wind them into the caps, removing the tang afterwards....

http://img.photobucket.com/albums/v2...250FE31195.jpg

Time to then build them up with the standoffs and HE sensors, along with cutting down a pair of stainless M5 capheads, so that they also don't protrude into the ABS wheel....

http://img.photobucket.com/albums/v2...F20BF3C63A.jpg

http://img.photobucket.com/albums/v2...16C71E28B8.jpg

Installed into the hub....

http://img.photobucket.com/albums/v2...5BBF773EFF.jpg

And cable routed and retained...

http://img.photobucket.com/albums/v2...6B55CE1630.jpg

Finally, refit the rear traction control HE sensor standoffs, all nice and black....

http://img.photobucket.com/albums/v2...F19F8C415F.jpg

And that's it for this evening. Bumpers and fire extinguisher tomorrow....

Pat RUFBTR 09-20-2015 02:49 AM

Spencer, I adore tone concerns(marigolds) of the detail! :)

Spenny_b 09-20-2015 03:16 AM

Hi Pat...you mean the black anodised vs the gold passivate bolts?

(In England, these are marigolds... :D;) )


http://img.photobucket.com/albums/v2...3ddb095d02.jpg

Pat RUFBTR 09-20-2015 01:57 PM

Quote:

Originally Posted by Spenny_b (Post 8802081)
Hi Pat...you mean the black anodised vs the gold passivate bolts?

(In England, these are marigolds... :D;) )


http://img.photobucket.com/albums/v2...3ddb095d02.jpg

:RÉ
Everything is thought well in greatest detail, I hope that one days I could make an equivalent in EFI on mine. I do not understand everything and thus that slows down me but that does not prevent me from being very admiring of your made work!

Spenny_b 09-20-2015 04:01 PM

Lots of progress this weekend...still no fire extinguisher activity, but still, many jobs now finished.

The front bumper is now bolted into position for the final time, the headlight washers plumbed in, and the freshly powdercoated reinforcement strips now banished from being stored in the house.

After this, the inner arches were installed - still can't believe how long these apparently easy bolting-in-place jobs take to do, time consuming to find the correct fasteners and get everything to realign with the new "speednuts" (panel clips). All fasteners given a quick spray with wax to protect from the elements....despite all this, I'm still a few fasteners short, God knows where they've gone, but I guess it's to be expected after 4yrs and countless moving around of parts boxes.

Next job was to reinstall the plastic steering rack cover - another large and fragile item gone from the workshop, but there was a job to do before it could be fitted; in addition to the plastic flange nuts that hold it, there are 2x M6x16 hex head bolts, however, somebody in the cars previous life had tried to remove the LH bolt, and sheared it flush in the aluminium cross beam. Some careful drilling, ensuring the hole was central, to try and use an extractor tool. This went fine, but the extractor tool didn't grip well enough (I never have success with the lefthand threaded tap-like tools, waste of space in the toolbox). So, time to drill and re-tap it to M6, which went perfectly smoothly, no snapped taps this time! So, the cover is now fitted.

Rear bumper and sharkfin next. I started this a few weeks ago, and for some reason I was struggling to get everything aligned but did eventually get everything tightened....then went back into the workshop and found the 2x U-channel supporting ribs that install under the flange of the bumper, sitting on the parts shelf....one sense-of-humour failure later and I decided to just leave it. I went back to it with a clear head this afternoon, installed the ribs and it all just aligned fine....weird! Whether by being installed for a few weeks, the plastics have re-shaped subtly, I don't know, but it's all now done.

The RH shark-fin supporting tie-rod is now fitted - I mentioned before that these were missing on my car when I bought it, so this was a good job done, and certainly adds rigidity to that bottom corner ahead of the rear wheel.

With the rear bumper attached to the rear quarter panel, it was time to finally tighten the 2x M12 mounting bolts at the back....and then time to line up the exhaust tail pipes and fasten them.

I spent a few hours yesterday messing around with the OE engine fusebox cover. With the new intake pipework, The fuses that were once mounted on the outside of the ally mounting plate have now had to be relocated to the inside, which wasn't too difficult, as there are quite a few items that have been removed, not needed when removing the CIS system. However, the plastic cover has a bulge to cover these external fuses, and needs to be removed. A few months ago I tried to make a new cover from sheet ally, but it looked a bit rubbish and was ill fitting. So, I thought I'd rework the plastic one, it's only a $12 item so no harm done if it all goes wrong.

I started by cutting out most of that bulge...

http://img.photobucket.com/albums/v2...F03014F7F0.jpg

Then had to enlarge it a little, before spending a lot of time making an aluminium panel that will fit behind the plastic. Lots of compound curves, so was quite tricky to make it accurately. The plan is/was to then get it powdercoated in satin black to try and match the plastis, but the lack of photos tells you that I'm not convinced this second attempt is going to look any good either. What I may do, is to install the ally fill-in panel, then use this as a template to take a mould from, then make a new unit, either fibreglass or carbon fibre (Rob, stand-by, I may be giving you a shout for some advice! I've never done any CF work, and very little FG, but you've got the knack mate!)

Last job this evening was to address the rear engine lid latch. Really annoyingly, after taking the trouble to source a very nice looking latch from the US and waiting for it to be shipped over, I noticed the other day that the engine bay lamp should be on, but wasn't. Some quick diagnostics showed that one of the wires from the microswitch has fractured...

http://img.photobucket.com/albums/v2...25E6BD0E89.jpg

Terrific. This part cannot be removed without stripping the whole bloody unit, which is swaged shut with 2 tubes that double as the mounting holes. If I was going to go to this much trouble, I wouldn't have bought a new unit, I would've stripped the one I had and got it re-plated (which was all that was wrong with it, it was just looking tired). Now I've got to retrieve the old unit, strip that one as well and swap over the microswitches....the wire sheared right up against the switch housing, so no way to repair without butchering the plastic.

http://img.photobucket.com/albums/v2...B8579A7460.jpg

http://img.photobucket.com/albums/v2...58D3A13412.jpg

http://img.photobucket.com/albums/v2...FF95C04735.jpg

I said earlier that there was no fire extinguisher activity - not quite true - I think I've got my head around where I want to mount the 4x nozzles in the top half of the engine bay, and the type of brackets I need to mount them. Whether I make them from steel or ally, they'll need plating, so at the same time, I may as well get the latch re-plated.

Time to hop onto p27 and cross off a few more jobs from the list....back in a few days...

Spenny_b 09-21-2015 03:47 PM

Fire Extinguisher Installation...
 
...at last...

Decided to just get stuck-in this evening, frustrating though it is to undo all the intake system in order to get to the back of the engine bay. I now REALLY wish I'd installed the pipework before putting the engine back in.

First job, decide how to run the hoses, where the T-pieces are going to be and then the nozzle placement....

http://img.photobucket.com/albums/v2...450A57BE4A.jpg

Then, run a mainline from the tank, along the tunnel and through the grommet behind the handbrake.

(none of the hoses are fixed in place yet, nor are the nozzles orientated correctly)

http://img.photobucket.com/albums/v2...50DB5FB851.jpg

http://img.photobucket.com/albums/v2...95C5BE5FF7.jpg

The tank has a dual outlet fitting, intended that one side remains in the cabin feeding 2x nozzles, then the remaining 4 go off to an engine bay. I'm not doing this, instead, the dual outlet will be replaced with a single outlet when it goes for filling, but this does now mean I'm a T-piece short, I need a 5th.

http://img.photobucket.com/albums/v2...67746A0E89.jpg

http://img.photobucket.com/albums/v2...5E826DAAE8.jpg

The mainline will then branch off using 2x T's; the main branch continuing into the top half of the engine bay. The lower branch to the lower half of the engine. Both the top and bottom will further split to feed left and right sides, then further split to supply left rear/left front + right rear/right front.

The lower nozzles will be L&R and aiming at the turbo and wastegate areas.

Each length of 8mm ally tubing has to have a heat resistant sleeve applied, and I decided to terminate each sleeve with glue-lined heatshrink...

http://img.photobucket.com/albums/v2...D1FDD1DDC8.jpg

So, this evening I got the mainline in, the continuation run to the top half of the engine, the intake system dismantled and the right hand feed in place, plus both nozzles installed. In other words, about a third of the way there! (albeit, the hardest third to get to)

http://img.photobucket.com/albums/v2...C46DC399EC.jpg

http://img.photobucket.com/albums/v2...EE3A24DE2E.jpg

http://img.photobucket.com/albums/v2...3D72CFBBE9.jpg

http://img.photobucket.com/albums/v2...D806E2C8C1.jpg

Work will continue tomorrow evening....

Spenny_b 10-04-2015 03:15 PM

Evening folks,

Some steady progress for the last few weeks, not much happening during the week, but some solid work being done this weekend.

The nemesis job - the fire extinguisher - is almost done. With so much "stuff" packing the engine bay, it's a chicken-and-egg situation with installing before or after the engine/gearbox goes back in...very easy to look back and regret not putting it in first, but it could have gone wrong with the positioning of the nozzles or the routing of the hoses potentially fouling something....so, I guess I have done it the correct way around...but BLOODY HELL it's a pain in the arse to fit retrospectively. I've lost count how many times I've smashed my head on the gearbox/heat pipes/dampers/brake discs, perfect ingredients for monumental sense-of-humour-failures. Anyway, it's almost done now, so I do feel as though I can start to think we're on the home straight.

I ended up dismantling the whole intake system (well, not the manifold), so that I could route the pipes perfectly, forming them around the chassis and ensuring that they're held in place nicely with either p-clips or the nylon straps that Porsche use onto the chassis studs. Very happy with how this now looks, discrete and OEM like...would look even better if the nozzles were black instead of blue! ;)

All 6 nozzles and their lines are now in, as-is the main run from the bottle. Not a lot to show over-and-above the photo's posted previously.

This weekend was spent doing a couple of odd jobs:
  • Re-coupling the AC lines from the engine bay to the chassis, inside the LH wheel arch
  • Fitting the transmission tunnel cover
  • Finish fitting the front undertray and fuel pump cover (needed the tunnel cover to be fitted first)
  • Finish fitting all remaining inner arches

So, quite a few large and bulky items now back onto the car and out of my workshop.

The rest of the time was spent changing the brake and clutch fluid on the Lotus, and making the 6 brackets to mount the extinguisher nozzles exactly where I want them to aim, either in the engine compartment or under the engine...

http://img.photobucket.com/albums/v2...92B3EAA15A.jpg

It all looks "remarkably unremarkable", but it's another job that looks simple but takes forever to cut, check, drill, bend, re-check, file, adjust, trim and then clean up with fine abrasive, ready for anodising (black).....will post more pics once they're back and mounted; hopefully somebody will find it useful in terms of where aim them and where to mount them from.

The bottle is away being filled with gas, hopefully will get that back midweek'ish. Next job is to wire the control box>big red switch>bottle....very simple, just a few hours with heatshrink, soldering iron and the multimeter.

Pat RUFBTR 10-05-2015 01:13 PM

Hi Spencer ! Courage for what remains in you to make on your car, you are there almost! ;-)

Spenny_b 10-12-2015 04:10 PM

Hey gang, a very brief update this evening....lots of thinking behind the scenes, but not a huge amount of progress that worthy of a detailed write-up or photographs.

Easy one first - the above brackets are now back with me, nice-n-black and mostly back on the car with nozzles installed and tightened.

http://img.photobucket.com/albums/v2...99C36C8DCC.jpg

The bottle is also back, filled and altered to remove the "T" fitting and install a single outlet...

http://img.photobucket.com/albums/v2...1B82319D9E.jpg

Next one, I'm onto brakes. I was hoping to make-do with the existing discs; they've looked tired since I took the car off the road, and I was aware of corrosion on the inner faces, but I had hoped that by removing them and spending some time with a wire brush on the end of an angle-grinder, they'd tidy up well enough for me to get the car mobile and do the low speed mapping. For sure, they'd get replaced before using the car normally, but this is just a case of postponing a £1,500 bill!

But...the fronts are way past recovery. The inner faces show evidence of only the central third having decent pad contact, the inner and outer diameters are really badly pitted. Also, when cleaning out the vanes and the inner bells, a tonne of rust was removed....worryingly of course, this is structural brake disc material.

I've not yet removed the rear discs/calipers.

A job I'd wanted to do since I bought the car, was to get the calipers refurbished and nicely repainted. This is now looking like a priority job, based upon the fact that tonight I removed the RH caliper to try and ID the pads (bizarrely considering the inner face issue, they felt very strong with great initial bite)...the inner pad was seized, no way was that going to slide nicely.

With what I could see with the pads in situ, I thought that a previous owner had perhaps installed Pagid RS4-2 "Blue" pads...signs of blue paint but again looking tired. Turns out they're a brand called "SBS"...not heard of them before, but some light Googling shows that they seem to be a brand well known in biking circles. There's about 9mm left on each, but seeing as I'm going to the lengths of a complete refurb, to skimp on pads now seems a bit daft.

So...thoughts are that either I go for:
  • Pagid RS4-2, which I *think* are installed into the front axle on the Lotus - frankly, they're the best brakes I've ever used, absolutely awesome for road use...neck snapping with warm R888 tyres (and, to be fair, larger floating AP discs).
    or
  • Pagid S compound - track heritage but marketed as a fast road pad. Initial bite and progression/feel are my primary requirements....this isn't going to see a track, so fade and pad heat transfer are far less important.

Anything that chucks metal filings out the wheels (Hawk) are no-go, and if they don't throw a tonne of dust over the wheels, that would be great.

I used Pagid RS-29's (yellow) on my previous GT3, a 6-pot caliper along with Alcon floating discs....not bad, initial bite wasn't the best, and were quite fussy in terms of bedding them in correctly. I never tracked the car, so can't comment on durability or resistance to fade (although they're supposed to be awesome)

So, the shopping list this week now has:
  • A set of 4 discs (Sebro, I'm really not fussed about having the Porsche box that they get delivered in)
  • New pads
  • New caliper mounting bolts
  • New damping shims (they weren't even fitted to the existing pads, probably to ease removal/refitting whilst doing some track work)
  • New rigid lines from caliper to hose
  • New stainless hoses

Regarding the caliper rebuild, robt964 over on Rennlist used a company called Brake Caliper Refurbs, who looked to have done a superb job. Speaking with Rob, a few years down the line and he's still very happy with their work, which involves vapour blasting to remove paint, triple sanding the faces to get them ultra smooth, then acid etching before painting/lacquering. Finally, a ceramic coating is applied (similar to a nano coating) that increases the resistance to brake dust.

I gave BCR a call this lunchtime to chat this through; for the work involved, including replacing all fluid seals, re-plating the spider clips, full refurb of the sliding plates, and if needed, new dust seals (I'll get them done as a matter of course) and new bleed nipples, it's money very well spent. You wont get anywhere near with a DIY effort by the time you buy the paint, seals, new screws, etc, etc..not to mention re-applying the Porsche logo on the faces. I have better things to spend my time on.

Check out their FaceBook page for plenty of examples of their work..... https://www.facebook.com/BrakeCaliperRefurbs

I think I've decided to go for red, a-la Porsches "S" models....a departure from the stock external look that I've gone for so far (apart from brake ducts and clear indicators), but it's a bit of a nod to something-not-quite-being-stock-under-the-hood ;)

So, about to be very broke again this week! :D

304065 10-13-2015 05:00 AM

Spencer--

Use the stock factory pads for street driving. They are the best compromise between cost, dust and fade. . .with the most important criteria being cold grip.

In my old '88 Carrera I used Porterfield R4S for autocross duty. . . and then decided to leave them in following the event. Took the car out one cold fall morning and hit the brakes. . . and kept going-- fortunately there was room in the next lane over behind the car ahead of me. . . all of which I used to get the car stopped before the red light. Lesson learned-- race pads for race, street pads for street and nary the 'twain. . .

Of course the sky's the limit on brakes. . . but I agree with your approach, restore the stock system for now. . . .I expect you will want more braking power to match your go power but that can be sorted out later.

Great progress on the last 10% that take 90% of the time!

Spenny_b 10-13-2015 02:41 PM

Hi John,

Yep, I'm decided on not going for a track pad for sure....the Pagid S range is very definitely marketed as a road pad, not track, and about half the cost of the Pagid RS (track) range...we'll see what they can do on price when I speak to them!

Pagid do give a nice set of friction numbers for their race range, and their RS-5 (another "Blue" pad) looks great, apart form there's no comparative numbers for their road pad range (the "S"), so it's difficult to judge whether 0.43 @ cold, and 0.45 @ 100ºC is better or not....I'm curious more from the Lotus angle rather than wanting to fit them to the Turbo; I did read on one of the sites who sell Pagid, that Lotus Motorsport (the guys who built my Cup240) choose one of the Pagid RS (the 4-2 iirc) as their pad of choice for upgraded models.

You're not wrong about the last 10%!! When I flick back to the beginning of the project write-up, what seemed to be at the time a very pedestrian engine build, was actually a lot more productive in terms of elapsed time vs jobs completed.

Cheers
S

safe 10-13-2015 02:51 PM

If you go away from street pads, then look no further than Performance friction. Beats anything pagid has. I have the PF08 and both pads and rotors lasts forever. Cold grip is a little worse than stock, buttstock not dangerously bad.

Spenny_b 10-13-2015 02:56 PM

A solid evenings work....messy, but productive!

All four corners are now dismantled. Having bought a set of Laser hose clamps, I can whole-heartedly say DON'T BOTHER....load of crap. The first one snapped the pivot on first use, the others twist so much that they don't effectively clamp the hose. They can go back.

So, time to must a collection of mole grips; the stock rubber hoses are going in the bin anyway.

All 4 link pipes from rubber hose > caliper now need replacing...thought they would, they twisted when undoing them, due to corrosion on the 11mm ferrule.

So, here's the motley bunch of black(ish) calipers....

http://img.photobucket.com/albums/v2...5F9A84AD76.jpg

http://img.photobucket.com/albums/v2...99ABAA8DA7.jpg

http://img.photobucket.com/albums/v2...A2ABDC8B15.jpg

http://img.photobucket.com/albums/v2...9597251975.jpg

http://img.photobucket.com/albums/v2...28BD25EFBC.jpg

http://img.photobucket.com/albums/v2...7E5D8E3544.jpg


And a stack of rusty iron....

http://img.photobucket.com/albums/v2...B56CE24DFD.jpg

The handbrake assembly also looking second-hand, so will probably replace these shoes as well, giving everything a thorough clean, and be done with it.

http://img.photobucket.com/albums/v2...2183DECB40.jpg

http://img.photobucket.com/albums/v2...C8D22B54FF.jpg

And the front hub assy....

http://img.photobucket.com/albums/v2...17078D04E5.jpg

I've just got to employ some self-restraint and not get sucked into stripping everything like backing plates, hubs, ball joints, etc, in order to start replacing or refurbishing...otherwise I'll still be writing updates on this project this time next year.

Spenny_b 10-13-2015 03:00 PM

Quote:

Originally Posted by safe (Post 8834701)
If you go away from street pads, then look no further than Performance friction. Beats anything pagid has. I have the PF08 and both pads and rotors lasts forever. Cold grip is a little worse than stock, buttstock not dangerously bad.

Thanks for the recommendation, Safe....have you tried Pagids road pad, or are you comparing to their race range?

Funnily enough, the vendor who I'll likely get the discs from are also a PF reseller...but as John said above, I really don't want to be sacrificing any cold bite performance ;) Very interested in which Pagid pads you've tried?

(brake pads, like engine oil is the stuff of religious debate the world over!)

safe 10-13-2015 09:58 PM

Quote:

Originally Posted by Spenny_b (Post 8834725)
Thanks for the recommendation, Safe....have you tried Pagids road pad, or are you comparing to their race range?

Funnily enough, the vendor who I'll likely get the discs from are also a PF reseller...but as John said above, I really don't want to be sacrificing any cold bite performance ;) Very interested in which Pagid pads you've tried?

(brake pads, like engine oil is the stuff of religious debate the world over!)

It was the blue pagid, don't remember the number.
Went down from using 2 set of rotors a year to a set of rotors and pads lasting for years.
However they are to aggressive for only Road use. If the purpose is Road I would go with original from Porsche. Important, from Porsche, not OEM from generic supplier. Not the same stuff...

Spenny_b 10-14-2015 12:00 AM

Quote:

Originally Posted by safe (Post 8835211)
....Important, from Porsche, not OEM from generic supplier. Not the same stuff...

The rear pads I removed last night are Textar with Porsche part numbers and the OE Porsche original parts logo; I already knew that Textar were the OE manufacturer, but when you say "from Porsche", I remember that I was told by a Pagid reseller in the UK that the GT3 original pads were made by Pagid, were indeed yellow in colour, but were a specific compound as described by Porsche, they were not RS-19 or RS-29's despite looking identical (and were not available direct from Pagid or a Pagid reseller, only from Porsche themselves)

Is this what you're referring to? I.e., Original Porsche part numbered pads are NOT the same as OEM Textar?


All times are GMT -8. The time now is 01:26 AM.

Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2025, vBulletin Solutions, Inc.
Search Engine Optimization by vBSEO 3.6.0
Copyright 2025 Pelican Parts, LLC - Posts may be archived for display on the Pelican Parts Website


DTO Garage Plus vBulletin Plugins by Drive Thru Online, Inc.