G50 Conversion Project Begins

[Shuie]

Very nice work. Another huge DIY project made simple at Pelican. Any reason you didn't sell the '72 and backdate a '87-'89 car instead?

[1972_911T]

Because then it wouldnt be a 72 the cream of the crop of 911's In the long run im not sure there would be much of a cost difference in making an 89 a realistic 72 replica both on the outside and inside as opposed to giving a 72 the mechanical reliability that comes with the later engines and trannies. Also owning a pre 73 car in the UK has the advantage of been exempt from road duty, not a major issue but one less yearly payment to fork out for.

Hows your 3.2 conversion going?

Steve

[Shuie]

fair enough. A backdated '87-'89 car wouldn't be emissions exempt here. Registration issues alone are a good enough reason for me to keep mine also.

My conversion is going slow, but its going. Finned Elephant Racing oil lines (and maybe the engine) get installed this weekend. I should have been done a month ago, but I took a detour and switched to coilovers in the rear.

[1972_911T]

but I took a detour and switched to coilovers in the rear.

G50 conversion planned down the line? if you've got coilovers it only needs a bit of chopping and stregthening to the tube.

Steve

[Shuie]

no, no G50. Just wanted coilovers. I'll probably sell or trade the car for a 964 after its done.

[adomakin]

Steve, Im looking at making a flat ally panel (with some ribs for strength) and perhaps using some dzus fasteners to fix it. as for my gearbox, standard 930 till it goes pop then G50 madness!

[1972_911T]

My new G50 tranny finnaly arrived yesterday ive spent most of yesterday afternoon comparing the late style endcasing that I have with the early one as ive not had much luck finding a used early casing, and new ones are aboout $1000. So ive been looking at ways to modify the late one to fit my early car.



So today I took the grinder to the casing to get rid of the excess bagage to start with.



Now I have taken enough material off the casing to make it fit the car I need to work out a way to get the mount to fit the bottom. The bottom of the early casing has a flat mounting section as can be seen in the picture of a G50 installed in an ultima.



And heres how my bottom is



My plan is to get a piece of billet aluminium machined to match the profile of the bottom of my casing. I can then have this drilled for the mounting studs then welded in place. All I will be left to do then is have the selector hole machined out to relocate the seal and the guide.

With the cost of the new casing its worth a try, the anoying thing is the later 964 big casing like what mine originally is is half the cost of the earlier one for some reason.

Steve.

[adomakin]

nice work Steve, grinding stuff up is scary, especially when its worth a big chunk of money!

[1972_911T]

Ive finnaly managed to get a bit of free time to make some progress on this project, Ive managed to sort out the issue of getting the seal and the guide from the end of the old mount into the front of the now shortend end case. What I did was to take the old section from underneath the front mount cut off the old mount then have this turned down on a laith to make an insert.



I then cut this down so it just had the bit that holds the seal and the guide bearing. The end case was then machined to take the insert which was then held in with loctite bearing glue.





Steve

[adomakin]

Nice work steve! a proper bit of engineering.

[1972_911T]

Ive now finnaly finnished fabbing the bracket so I can attach the original 87 - 89 tranny cradle.







In the end its cost me about £80 to modify the G5003 to fit the same as the 87-89 G5001. Ive also discovered the G5003 has the G5050 bearing retainer so should be stronger than the G5001 which is an unexpected bonus.

Now that the tranny is ready to fit, ive just got to do a bit of tidying up of my welding in the back and to sort out the line for the hydrolic clutch then I should be good to go.

Steve

[herman maire]

Nice work steve..... Did you just cut the shift rod and tap a hole in it?

This is a damn good idea.... I like it alot

What are your plan for the bell housing?

[1972_911T]

I actually cut a length out of the middle of the shift rod and welded it up, I cut it lower down on a section that doesnt run through the seal and guide bearing. Also on the 964 tranny there is a section of the selector shaft that has notches cut in it and it has a sprung loaded ball bearing, I think this is used to give the gears a better feel when selecting this is absent on the early trannies and had to be cut out or else the notches would run through my newly located seal and hence screw up the seal. The selectore mech is identical to the early ones (I checked the part numbers on PET) without this so I dont think it is a problem to remove it. You can see where this used to be in my pictures, the case is welded where the spring mech went into the side just behind the seal.

Im not sure what you mean about the bell housing? The end bell housing on the 964 is the same (same part number) as the early 87 - 89 trannys so doesnt require any modification to mount to the earlier engines if this is what you were asking.

Steve

[89turbocabmike]

Wow, very nice progress Steve.

[724doorE]

How much longer is the 6 speed from the 993? I mean will it fit where a G50 would fit?

[1972_911T]

No the 6 sp requires alot more work, its about 3 - 4 inch longer and requires removal of the centre of the torsion tube and also substantial work to the floor bulkhead and seating area. There is a thread running recently where this has been done.

Here it is 3.9 RSR project --- my Carrera reborn

Steve

[SteveM911]

Good luck with your project Steve, very brave and you are making it look so staight forward to do.

Well done.

[1972_911T]

Been a long time since I posted on this thread as my conversion has take a bit of a de tour that turned into a full bare metal paint job now thats nearing completion and im approaching the rebuild I need to face my finnal problem of this conversion. That been the pedal cluster, I need to use the late pedal setup as its almost impossible to get at master cylinder mounted to the early pedals for the clutch but then this causes me another problem with the brake master cylinder as I dont have boosted brakes. Has anyone else managed to get a early non boosted MC to work with the later pedals?

Steve

[shahram]

subd.