G50 Conversion Project Begins

[1972_911T]

After a lot of carefull deliberation backed up by coming across a good priced G50/03 with LSD from Harald in germany I have decided to do the conversion. After weighing up all the three major options I have decided to go down the route of torsion tube replacement. Im not keen on coil overs and have not been able to find a shortend G50 option for the 3.2 DME. So torsion tube replacement it is.

As I have not found any posts on this forum detailing the procedure I decided I would start one, to put anyone else off attempting this carzy idea.

I started out by leveling the car an stands making sure the car was 100% level I used stand in all four courner and aditional support at various palces around the back of the car to make sure there would be no strain to potentially twist the chassy with the tube removed. Im not sure exactly how much support the tube provides also having the big suspsension cross member not that far away from it but didnt want to take any risks.

The next step was to build a frame around the torsion tube to provide some thing straight and level to make measurements from this will also act as a jig to aid alignment of the suspension banana arms mounts.



The torsion tube mounted banana arm mounts bolt to the jig making sure the are set at the right height.



The Idea is that when my new torsion tube is cut to size and centralized I will have some inserts about 6" long turned down on a laith to be a nice snug fit inside the torsion tube. The insert will be put inside the remainder of my old tube before the new peice is put in. Then I will slide the inserts through into the new piece so there is a 3" overlap this will ensure my tube is perfectly straight the inserts will also strengthen the joint and will be spot welded at various points to hold them in place when everything is lined up. The centre of the tube can then be turned untill the bolts for the banana arm mounts locate with the jig ensuring this is aligned correctly. I will then double check all the measurements I took before torsion bar tube removal to confirm correct alignment and if all is good proceed to weld in the new tube.

I will add to this thread as I proceed to let you know how I get on.

Steve

[1972_911T]

In too deep!

With my jig and measurement taking completed I proceeded to remove the T bar tube. I cut the bar by making a small slit in the back seat then using a reciprocating saw that made light work or cutting the tube.



Once I had cut through both sides the tube reamained perfectly in place bolted to my jig giving me some confidence that this crazy idea may work. However due to my jig and the fuel lines etc it was clear to see the old bar centre wasnt going to come out. The means I had to cut through the rear floor seat section and remove it up through the car. This isnt a major issue as holes would have to be made get to the back or the bar for welding.





No going back now!

[RideShoot&Drink]

May God be with you! I wish you luck and very interested in your project, as I have G50 sitting in my garage now!

[1972_911T]

I have now sourced the replacement torison tube for my conversion I cut it out as close to the frame rails as possible giving me plenty to work with.



The G50 tubes are quite a task to remove as they have extra mounting supports to the seat floor and the front of the torsion tube.



I alos got an added bonus of getting the rear seat area I previously over looked this part however after looking at it more closly I think its a big benefit to have this as it has the other half of the support mounts. As these were cut with thin hack saw blade they should weld right back up to where they were cut from on the torsion tube when I weld this new seat floor in.



Steve

[89turbocabmike]

Your a brave man! Thanks for sharing this insanely cool project. The G50 is soo worth it

[jevvy]

As I've said before Steve, you are a braver man than me - good on yu.

Good luck with the project and keep us posted with pics

[1972_911T]

Dont worry Dave if it all goes wrong im blaming you, after all it was driving your car that started my G50 yearning!

Steve

[kycarguy 935]

I put a G50-50 in a 87 911 turbo in 1992 and went through the same long process changing the torsion tube,pedals,shifter and the hydraulic master and ran a stainless tube for the fluid. Looks like your doing a nice job. Keep up the good work.

[1972_911T]

Looks like your doing a nice job. Keep up the good work.

Thanks for the words of confidence kycarguy 935. Ive just had a week away in greece and now back rareing to go hoping to get the tube in tmrw.

Can you remember what size the hydrolic tube was for the clutch? Ive not got any of the hydrolics yet and woundered if it was the same as brake line pipe. I did consider just getting one braided hose made up to go right from master to slave cylinder but this may cause problems if it ever needs replacing.

Steve

[dean]

Originally posted by 1972_911T

Can you remember what size the hydrolic tube was for the clutch? Ive not got any of the hydrolics yet and woundered if it was the same as brake line pipe. I did consider just getting one braided hose made up to go right from master to slave cylinder but this may cause problems if it ever needs replacing.

Steve

I used -6 or 5/16" tubing for the clutch line. I think the idea is you need a fairly big line cause you are moving a lot of fluid fast in the slave.

[herman maire]

This is going to work out perfect.

I bet it was a great feeling to just get in there and start cutting. I love that "No turning back " feel .

I have planed the extact same thing. I even have most of the parts in the shed,
I am determined to give a custom 915 box one last chance though.

I look forward to seeing this get welded back together

[kycarguy 935]

I don't remember the size I used but the size Dean is using sounds like the size I used.

[dozer]

Would you do me a favour and measure the distanse from center to torsion tube?

[1972_911T]

Hi Dozer can you clarify what you want me to measure? from the centre of the torsion tube to the centre of the swing arm mount? or from the centre of the tube horizontaly to where the thick part of the tube starts?

Steve

EDIT

Ok just noticed the arrow on your pic I see what you mean now I will measure later!

Steve

[1972_911T]

Made some good progress today and got the tube tac'ed in place!



I had to give the panel that comes up from the floor to the seat quite a bit of a beating to get the tube in I also had to cut short the two tubes that stick out where the two wiring looms come out of the body as these were fouling in the front of the tube.

Unfortunatly after I tached the tube in I went back and checked all my measurements and im 1mm out left to right so tmrw I will have to grind off my tac's and budge it along a little other than that all seems well.

[dozer]

Thanx Steve
That would be greate!

Realy nice job youre doing here.
1mm..... so close:-)

[1972_911T]

Dozer the distance you asked me to measure is 100mm to as close as I can measure it!


Steve

[dozer]

You are greate help Steve! Thanx

[RickM]

Awsome project. Subscribed to thread.

[vash]

amazing! very...........