RSR Update

[PrimeMvr]

How's it coming Motley? Spring might just come one of these days. Amazing project, I'm in awe!

What part of IA are you in? I'm in Dubuque where I think there are a whopping 4 P-cars.

[motley911]

PrimeMvr. We're neighbors - I have 2 of the Porsche's that live in Dubuque. I know 4 other P-car owners in Dubuque, so I am glad to hear the numbers are growing.

Spring - I was hoping to have the RSR finished by now but work keeps getting in the way of progress. I am currently reassembling the engine after having all of the parts powder coated and still hoping to have it running soon.

I still haven't got my 930 cab out of storage yet as I wanted to finish the RSR and don't need any distractions.

I will post some pics of the latest work soon.

Richard.

[MikeD930]

I just noticed in your sig that you own an ex-IA 930 conv. Did you buy this car from the owner of now defunct IA? If so I remember that car for sale...it had lots of mods to suspension and engine along with Gumbella (sp?) body style.

Looking forward to your completed yellow beast.

[motley911]

MikeD - yes thats the one. It has a Gemballa body kit fitted that needs a lot of TLC. Originally, I was looking at purchasing the engine and transmission out of the car and Stephan did me a good deal to take the whole car. Once I got it home I figured (or more correctly, my wife decided for me) it was too good to part out - hence why I have 2. The engine is really well sorted and it surprises me every time I drive it. At the end of last year the clutch started giving up at full boost in 3rd and higher so I have a bit of work to do before I get it out for this year.

The yellow beast is getting closer to being finished - but I still have a lot of small details to complete.

Richard.

[onboost]

Originally Posted by motley911

MikeD - yes thats the one. It has a Gemballa body kit fitted that needs a lot of TLC.

Once I got it home I figured (or more correctly, my wife decided for me) it was too good to part out - hence why I have 2.

Richard.

Wow, an excellent wife! Kudos to her!

[motley911]

I thought it was about time for another update.
I have been trying to tie up a lot of loose ends with the build - this seems to be a never ending task from the front, to the rear and then onto the engine.

I sent all of the parts out for powder coating. I decided to keep the engine colors low bling to contrast with the bright exterior and engine bay. Satin black on the engine tin. Metallic gun metal Grey on the valve covers and the fan.




I brought some generic turbo drain tanks and modified the flanges to suit the bolt patten of the K24 center sections. I also added a -6 vent port to the top of the tanks. Plumbed them all with SS hose (engine was upside down in the stand).



I tee'd the 2 vent lines together and ran the vent line to a port in the breather cover.


After countless hours trying to make the late model Porsche (996) COP's fit into either the 911 or 964 valve covers I decided that this just wasn't going to work without a lot of other modifications. The final nail in the coffin was the interference of the COP's with the oil lines for the cam towers. I decided to stay with the COP idea however brought some AEM pencil coil units and a pair of 8 channel CDI units. As I have twin plugs, I set up 2 identical systems, one for the top plugs and one for the lower plugs.

[motley911]

continued.

COP's fitted to 964 valve covers. Theses are the "long" AEM units. I fitted some O-rings to the COP's which fit snug into the valve covers - these are not going anywhere.







With wiring harness for the top plugs in place.

[DW SD]

WOW - awesome job! that harness is looking nicer than factory. Excellent!

Doug

[9elf]

Originally Posted by motley911

While working on the rear seat panels the suspension components where sent out to "Half Baked Powder Coating" in WI. They did a real nice job and turned the parts around in less then a week.
And finally the RSR struts with lowered spindles and Rebel Racing spring kit - pure mechanical porn



With the front suspension in place, I will be moving onto the G50 Pedal assembly and brake master cylinder conversion next.
Richard.

G'Day Richard.

Did you have any trouble with clearance between the front sway bar lever arms and the coils around the strut?

Great build mate!!

Craig.

[motley911]

DW SD (Doug) - Thanks for the feedback. The loom has taken a lot of work to get it to its current state. A good friend of mine Ben, who is also a P-car nut, is the one that deserves all of the credit. He endured several changes in direction that resulted in starting all over again 2 different times - the last being the change to the AEM COP's. Going to EFI and COP's I wanted to make sure that the wiring wasn't going to cause any issues.

G'Day Craig - good to here from someone from down-under. There is a reasonable amount of clearance between the coil over and sway bar arm. I was just down in the garage with the camera so I snapped a picture to show the clearance. This photo is with the suspension at full travel (extended) and due to the geometry the clearance increases slightly at ride height.



Richard.

[winders]

Richard,

That looks familiar!!





Nice project, by the way!!

Scott

[9elf]

Thats great, thanks Richard.

I'm about to install the exact same sway bar.

In your experience, would you say this location for the u-tabs is correct? (pic stolen from another thread)



Thanks again mate.
Craig.

[motley911]

Scott - that is some serious hardware you have there and a nice color to also I reversed the sway bar lever arm (turned it upside down) to give a small amount of additional clearance, resulting from the offset machined into the arm/clamp boss. Its probably not needed in your case due to the 935 front suspension but helped with my install.

Craig - I think that is the same diagram that I used when I installed mine. 12 cm from the outside edge of the arm is what I used and it fits well.


Richard.

[winders]

Originally Posted by motley911

Scott - that is some serious hardware you have there and a nice color to also I reversed the sway bar lever arm (turned it upside down) to give a small amount of additional clearance, resulting from the offset machined into the arm/clamp boss. Its probably not needed in your case due to the 935 front suspension but helped with my install.

Richard,

Yes, my front suspension is at more than full droop in that picture so I have plenty of clearance.

I saw what you did at the rear so I figured you would appreciate this from the rear of my car:



I love the RSR look. I can't wait to hear how it all truns out for you.

Scott

[Packy]

Originally Posted by winders

Richard,

That looks familiar!!





Nice project, by the way!!

Scott

What is the little red box for?

[winders]

Originally Posted by Packy

What is the little red box for?

That is an AMB transponder. Each one has a unique ID and is used for lap timing and race scoring.

Scott

[motley911]

More progress.

Engine Wire harness is now complete.





RS Carpet kit installed. Bob at APPBIZ was most helpful with sourcing some extra felt material for the rear seat delete. I have also installed the dual AEM CDI units for the COP's and installed the air filters.





The previous owner had fitted are nice double DIN GPS/CD/DVD player into the dash. Unfortunately it doesn't suit the new look of the car. So I removed the unit and fitted some gauges into the housing that was made into the dash. Oil pressure, Oil Temp and a Dual Wide-band O2 display. I also found a really nice 80mm boost gauge that filled the clock hole perfectly and made up a switch panel to replace the heater contols.



I then removed the original oil temp / pressure gauge, gutted the housing and fitted some LED warning lights - these tings are super bright, so no reason for not noticing them.




Richard.

[motley911]

Electrical system. The ECU panel mounted under the left hand seat. Haltech ECU and a J&S safeguard system.


And a picture of the rear relay panel. Dual O2 control unit, fuses, relays and a boost control solenoid.


Richard.

[kojo911]

what type of boost gauge is that?

[motley911]

Kojo - It is an 80mm Boost gauge from Prosport. It is a servo driven gauge, has lots of neat features and fits perfectly in the clock hole using the OEM rubber mount. Here is a link:
80mm Boost-Prosport Gauges 3 color display with shift light Peak/warning.Blue Racer gauge, White racer gauge

I also installed Prosport Oil Pressure and Oil Temp gauges. Again they have some nice features (peak warn, audible alarms etc.) including provision for remote warning lights - which I mounted in the old oil gauge housing.