Evolution of a Carrera RST

[jpnovak]

Been following this from the beginning. What a great build. Can't wait to see it finished.

Jamie

[Fixer]

I just skimmed this thread, awesome build Uwon. Good luck with your beautiful RST.-Matt

[Uwon]

[QUOTE=cxgh;8953974]I wonder if this case will lead to policy exclusions (if we hear you have ever been on a track then any claim will be void)?*********

See post 18. I would like to leave it at that.
Johan

[Uwon]

Jamie and Matt, appreciate your comments. Thanks.
Johan

[Uwon]

Finished the frunk electrical system, HVAC, etc. and installed hood.

.

You may recall that this is a short hood chassis with a long hood that uses the short hood latch mechanism.



Installed refinished gas tank and finished off the 16" spare tire in the same silver paint used on the rims. Had to do the leather strap thing .



Cheers,
Johan

[SpyderMike]

That looks real nice Johan!

[Uwon]

Thought it best to take some "selfies" of the front underside by placing the iPhone on the garage floor. This area will never be this clean again.











Cheers,
Johan

[Uwon]

A couple of setbacks over the last little while.
First, I missed that the master cylinder and booster from the donor crashed car was bent before installing it so when I tried to charge the brake system, I ended up with a booster canister full of brake fluid which overflowed into the frunk. Out came the water hose rather quickly. Fortunately the gas tank was not installed. You can read more about this misadventure elsewhere on this forum. Fortunately a fellow Ontario Pelican had a really good used booster which I married with a brand new, a.k.a. Expensive new 930 master cylinder.
Note bent unit:


Front of master-hollow piston end should be round:


So while I was waiting for the new master cylinder to come from Germany, I finished off the fuel delivery system and charged it (pressurized it with the fuel pump without turning over the motor) with our Canadian 94 octane gas which promptly revealed a terminal fuel leak at the "T" junction of the t-fuel line which lies underneath the intake manifold. My choices were to dismantle the top end of the motor to remove and replace with a new Porschee issue, OR, bend and jank out the old one and replace it with a "soft"T-fuel line manufactured by fellow Pelican Len Cummings, all which does not require R&R of the whole intake system. Anxiously waiting for my package from Len!
The culprit:


On a more positive note, I tidied up the frunk. There is still some tape wrapping to be done of the wiring which I will undertake once the car is fully roadworthy. I really have little respect for my electrical abilities which makes searching for an electrical gremlin a dawnting task, especially for me. Leave it to me to add 7 additional fuses underneath the dash, 3 more on the main board, as well as a sh* t load of relays:


Also installed all the parophenalia for the HID headlight system in a sub panel at the front:


Finished off with some Rennline goodies:


Frunk basically done.
Cheers,
Johan

[Tremelune]

Zip ties in the unused fuse spots...I like that.

Can you tell me what those standard relays are mounted in? I always have trouble finding female relay connectors that take standard pins or don't already have too-small wiring attached.

[vintagecarlover]

Looks awesome. I'm very interested in what all went into the new fuse and relays u added and what's all the relays?

[Uwon]

Originally Posted by Tremelune

Zip ties in the unused fuse spots...I like that.

Can you tell me what those standard relays are mounted in? I always have trouble finding female relay connectors that take standard pins or don't already have too-small wiring attached.

Relays are mounted on an upside down T shaped aluminum bar (roughly 2" wide, 1/8" thick. Roughly takes the contour of the fuse box and hangs on one fender bolt.
Hella relay base.
http://www.hella.com/hella-us/assets/media/HINC_Electrics_Catalog.pdf
Page 58, third one down. They interconnect. Got them locally from Carquest here in Canada.
The female connectors with the little tabs that locks them into the base I got from Dell City in the U.S. Also got a reasonable crimping tool which is in valuable.
Hope this helps.
Johan

[Uwon]

Originally Posted by vintagecarlover

Looks awesome. I'm very interested in what all went into the new fuse and relays u added and what's all the relays?

I put in relays for the oil rad cooling fan, fuel pump/injectors, coils, A/C cut out to avoid stalling on heavy deceleration all controlled thru programming into the Electromotive tec3r. Also added relays for low and high beams. Fuses were added for all live feeds to the relays, i.e. terminals 30 and 86. Also added fuse for the instrument lights which Porsche forgot.
Johan

[Jonny042]

Great work Johan. Looking forward to a ride in this thing someday

[Uwon]

Originally Posted by Jonny042

Great work Johan. Looking forward to a ride in this thing someday

Jon, you are most welcome to drop by any time.
Johan

[Uwon]

The new "soft" T-fuel line finally arrived from Len Cummings. Nice product, well made as one would expect from Len. It was easy to install-highly recommend this type of fuel line if you are not hung up on originality.



Fuel pressure tested with no leaks.
Made sure all the oil lines were still charged with oil before I turned the motor over with the coils and fuel pump on, and voila! motor fired up and first settled into a rolling idle. A bit of gas and warm up for 20 minutes....



No leaks-can't believe it..... until I carefully examined the bottom of the motor. Screw driver is pointing to the exact location of the leak between the stud and the bolt..



A closer look....




I have not yet re-torqued or restarted the motor. Thought that I would first seek some suggestions from the Pelican Brain Trust before going any further to solve this issue. So, if you have any suggestions, please bear in.
I have cross posted into the Engine Building Forum so hopefully between the two I will get some ideas.
Thanks in advance.
Johan

[Jonny042]

Congrats on the startup!

In the second pic of the leak (the one without the screwdriver) that's not a crack in the block, is it? (EDIT - NO IT ISN'T)

Read the replies in the engine forum, good advice there. How long has the engine had oil in there? Perhaps the leak isnt really THAT bad, is it a single drop of oil over a period of months?

[Uwon]

Jonny,
Left over sealer and shadow is playing tricks. Here is a pic after initial cleanup.

Johan

[911 Rod]

Hi Johan!

We've talked about your car, but I didn't know this thread was here.
I just read all 10 pages and it looks amazing!

Hope to see you at Mosport this year.
Rod

[Uwon]

^^^
Hi Rod,
Thanks for your kind comments. Yes, I'll be st Mosport in early May.
I can also report that the oil leak has now been fixed thanks to the advise received in the 911 Engine Rebuilding forum particularly John Walker's Workshop. Got to love these forums!
Car is now approaching completion and I hope that the weather warms up here in central Ontario soon to do a real road shakedown.
More pics soon.
Cheers,
Johan

[911 Rod]

Just to let you know what kind of stand up guy Johan is.
He still attends DE events (2 hours from his home) as an instructor even though he has not been able to drive his car during his rebuild.