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Winter Project Gone Wild? ...

... or just your typical slippery slope.

After losing the #2 rod bearing on my 1985.1 NA track car in September, my winter project was simply to rebuild the engine with some reliability and performance upgrades and to strip some more weight from the car. That engine rebuild is being covered in a thread on Rennlist. And a version of this thread is on Rennlist, as well.

For weight reduction, I planned to remove the rest of the interior carpet (rear was already done) and to do an AC delete. Once I got got all of the AC out, I figured I didn't need heat either. So a heater delete, then while I was in there ... ripping out the dash, alarm system, cruise control, unused wires, etc. Now with the car being that gutted, it seems like a good time to replace the bolt in roll bar with a full cage. The cage will have nascar bars on both sides, which means gutting the doors and fabricating manual window function so it will still be weather tight.

Guess it sounds more like a slippery slope.

Here is the current status. Engine out, donor engine (1988) torn down and most of it is in the hands of Lindsey Racing right now. The carpet and insulation has been removed as well as the dash and everything behind it. All wiring harnesses except one have been removed and I've removed most of the unnecessary wires from them. The motor that allows you to open the hatch from the driver's seat has been removed. And yesterday I removed the roof lifting mechanism and gutted and cut the right door.

Next on the list:

Gut and cut the left door
Clean up all the glue and remaining traces of insulation
Repair cracks at the left rear seat mounts (maybe fabricate new seat mounts)
Remove the windshield (for cage installation)
Have cage welded in
Seal up the holes in the firewall left from the AC, heat and vent delete
Install some new heat insulation on both sides of the firewall
Prime and paint interior
Wire in a battery cut off switch
Modify dash to include the gauges I had in the center console and some new switches
Put it all back together, including a 3 piece cross member
Build, install and break in the engine

Working a few hours at night and most weekends, I hope to have it all done by March.






And the cracks at the seat mount




And the gutted and cut right door



I don't plan to keep much of what is being removed. So if there is something you need let me know.

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Glenn
Daily Driver - '78 911SC RoW, Track - '85.1 944
Support vehicle - '00 Suburban 2500 4x4
Wife's - '11 Mini Cooper
Son's - '85.1 944
Old 12-15-2019, 05:53 AM
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Glenn, it looks like you are doing things the right way.

I would take out the reinforcement bars in the doors as well, since you are going to have your cage to protect you.

Fix up the seat mounts with some stitch welding, after removing all of the undercoating in that area. I had to do that on the '88 shell I swapped to after my car was totaled when I messed up.

I would not worry too much about adding heat shielding on the firewall afterwards - I have not done it on any of the 3 924's I have built.

Now is a good time to upgrading the suspension points with Delrin/Urethane if you haven't already. Also, urethane your transmission mount if it's the single piece design.

Looking forward to seeing the progress...
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NASA/PCA Instructor: '88 951S - with LBE, Guru chips, 3Bar FPR, 1.3mm shimmed WG, 3120 lbs, 256 RWHP, 15 psig boost
1987 924S 944 SPEC racecar - '88 pistons/DME, short 5th
1987 944S - Restored salvage title, ready to live again
I can fix your late 944 Cruise Control module - PM for details
Old 12-15-2019, 07:20 AM
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Another new 4 cyl wasserpumpfer project, and from a guy with other excellent projects here on PP.

Will you paint it yellow Glenn?

best, John
Old 12-15-2019, 07:38 AM
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Quote:
Originally Posted by jjeffries View Post
Another new 4 cyl wasserpumpfer project, and from a guy with other excellent projects here on PP.

Will you paint it yellow Glenn?

best, John
I kinda like the Pastel Beige. It is an uncommon color and gets more than its fair share of complements. So no color change for the exterior. I am thinking about a brown for the inside since that was the original interior color.
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Daily Driver - '78 911SC RoW, Track - '85.1 944
Support vehicle - '00 Suburban 2500 4x4
Wife's - '11 Mini Cooper
Son's - '85.1 944
Old 12-15-2019, 08:29 AM
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I can sympathize with getting carried away.
One day years ago I went outside to vacuum my car... In an hour or so I had pulled the seats and ripped out all the tan carpet and ordered new black carpet to put in..lol
Old 12-17-2019, 08:33 AM
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Quote:
Originally Posted by v2rocket_aka944 View Post
I can sympathize with getting carried away.
One day years ago I went outside to vacuum my car... In an hour or so I had pulled the seats and ripped out all the tan carpet and ordered new black carpet to put in..lol
It happens to the best of us.

Update: Slow progress, is still progress.
Got the driver's door gutted and cut. I also removed the quarter windows. I hope they go back in as easily as they came out. And I have started removing the glue residual.

Made a decision on interior finish. I am going to fabricate a lightweight carpet set, similar to the 911 RS, carpet kits to use in the rear of the car. The rest will remain bare (but freshened) Pastel Beige paint. Perhaps with the cage painted brown.

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Glenn
Daily Driver - '78 911SC RoW, Track - '85.1 944
Support vehicle - '00 Suburban 2500 4x4
Wife's - '11 Mini Cooper
Son's - '85.1 944
Old 12-23-2019, 05:13 PM
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Removed the windshield yesterday. Not a super fun project. The hard part is removing the trim. First you pull out the rubber seals between the aluminum trim and the glass. That was easy. But that revels the challenge. There are a bunch of spring clips that have to be slid to one side to release their grip on the trim. I used a screwdriver and gentle tapping to get them to move. The top clip on both sides was rusted. So I ended up destroying those ($8 to $10 each). One trick I found was to dig out the windshield glue from around the clip before trying to move it.



Once the clips are out, the trim can be pulled off, carefully. The driver's side had a ton of windshield glue that made it more challenging.



Getting at the clips on the top piece of trim was virtually impossible. Fortunately, using an interior trim tool and working gently from one end to the other, I was able to remove it without loosening the clips.



Next was to use my new Harbor Freight windshield removal tool (a wire between two handles) to cut the glue so I could lift off the glass.
The glass was pressed so tight to the frame that in trying to feed the wire through, I cracked the windshield.
Then when I completed running the wire around the windshield, I found that the windshield glue hadn't completely released its grip. And in trying to lift off the now cracked windshield, I cracked it again.

Lessons learned: take your time, don't force it, or better yet, hire someone else to remove the windshield.

I will have the new windshield installed by a pro. Fortunately, it appears new windshields are not horribly expensive.

Next is to remove all the leftover adhesive. That will not be a fun job, either. However, I did discover while trying to clean that crap off my hands, that WD-40 dissolves it.
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Daily Driver - '78 911SC RoW, Track - '85.1 944
Support vehicle - '00 Suburban 2500 4x4
Wife's - '11 Mini Cooper
Son's - '85.1 944
Old 12-26-2019, 04:53 AM
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Well, life got in the way again and not much progress has been made. But the little I have completed brings me to a milestone. The car is now ready for the cage install. Cage kit will be shipped to my installer this week and I plan to take the car to him this weekend, before life takes me away from the project again for a few weeks.




Also got good news from Mike at Lindsey Racing. They have finished all the work and they were just about ready to ship it all to me. But I stopped him. Since life is eating up more time than I had allotted for, I'm going to have Mike assemble the short block and bolt on the head before shipping it. So, I've got a few more parts to pack up so he can do that job. He has done so much already that going the rest of the way wasn't that much more.
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Daily Driver - '78 911SC RoW, Track - '85.1 944
Support vehicle - '00 Suburban 2500 4x4
Wife's - '11 Mini Cooper
Son's - '85.1 944
Old 01-13-2020, 04:59 PM
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Mike and Dave are great to work with. just talked to them for more parts for rebuilding my 951/DE engine. working to have it ready for the DE season.

not gutting the 951, but for my 930 .....


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84 928S, Ruby Red linen/brown interior - preferred DD
87 924S resurrect and gut and another track car...
86 944 turbo my new DE/track car.
78 930 clone project car.
Old 01-14-2020, 06:37 AM
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Quote:
Originally Posted by 911tracker85 View Post
{snip} ...not gutting the 951, but for my 930 .....
My SC was in a similar condition several years ago. Sometimes I would just look at it and the gravity of the work ahead made me question my sanity.

On to the update ...

Got an email from Mike today. He hopes to finish his part of the engine assembly tomorrow. Then it will come back to me to finish (all the easy stuff). I thought I would share a portion of the email where he describes his approach to the rod bearings.

"... Regarding the rod bearings, I got the ACL bearings in. We made a standard size and a .001" undersize. What I do is I measure the journal diameter, they set my dial bore gauge to the crank. I am shooting for .0022"-.0023" bearing clearance. I had some of each of the bearings coated by Calico, the coating is .0002" thick. The ACL bearings are good enough to run without a coating, but what the coating does is gives me the ability to combine coated and uncoated standard and undersize bearings to dial in the exact clearance I am looking for. On your crank I used a coated undersize bearing on the rod and a standard uncoated bearing on the cap. This combination put he clearance right where I wanted it. If you were going to be spinning this higher, like a dry sumped engine could spin, then we would have used 2 undersize bearings, one or both coated, it all depends on the particular crank its running on. I would go for .0025"-.0026" for that.

I put the coated bearing half on the beam of the rod where the highest load is. These bearings have more eccentricity than a stock bearing, the clearance at the parting line is .0008" greater than on the center line, a stock bearing is less than half that. This lets more oil fill that gap which increases the pressure under the bearing when it comes on load. These bearings have the same thickness at the parting line, which lets us use any combination of the standard and undersize bearings. The coating does give a slight amount of different dimension at the parting line when using one uncoated and one coated, but its only .0001".
"

Call me strange, but I found that interesting. Oh, he promised pictures, too. I'll share those when they come in.

I had to spend a few weeks in Florida helping out while my Mom recovered from surgery. (I head home this weekend) So I brought the nose, rear and dash wiring harnesses with me. I stripped out everything I don't need, documented every remaining wire and put together a plan to put it all back together. I am going to eliminate the stock fuse and relay blocks and reposition those components to be more easily accessible.

I will try to reuse the nose and rear harnesses. But the dash and power distribution will all be replaced with Mil-Spec wire (M22759/16). The wire has been ordered along with some new toggle switches.

There were some delays with the cage kit but it is in the hands of the installer now.

With all of this coming together, there should be more, and more frequent, updates in the coming weeks.
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Daily Driver - '78 911SC RoW, Track - '85.1 944
Support vehicle - '00 Suburban 2500 4x4
Wife's - '11 Mini Cooper
Son's - '85.1 944
Old 02-06-2020, 02:59 PM
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Pictures!!!






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Daily Driver - '78 911SC RoW, Track - '85.1 944
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Wife's - '11 Mini Cooper
Son's - '85.1 944
Old 02-07-2020, 04:08 AM
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Valentines Day gifts?


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Daily Driver - '78 911SC RoW, Track - '85.1 944
Support vehicle - '00 Suburban 2500 4x4
Wife's - '11 Mini Cooper
Son's - '85.1 944
Old 02-14-2020, 12:07 PM
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Cage install is almost complete. The Hanksville kit is so tight to the frame that there was little room for variations in their mock-up car and my car. Some trimming of the cage kit was needed along with "reshaping" of parts of my car to get it to fit. Unfortunately, that is driving the install costs up, but it will be a good fitting cage.

I've got some engine parts out for a fresh application of yellow zinc and others getting powder coated. (Because good looking motors make more horsepower. )

I've booked a couple DE's so I have committed to be finished, including engine break in, before May 2nd when I run Pitt Race with Auto Interests, then its off for a 3 day Potomac PCA event at WGI 2 weeks later.

I've got a lot to do before then.
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Daily Driver - '78 911SC RoW, Track - '85.1 944
Support vehicle - '00 Suburban 2500 4x4
Wife's - '11 Mini Cooper
Son's - '85.1 944
Old 02-18-2020, 05:25 PM
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Quote:
Cage install is almost complete.
just started the process of fitting my cage in the 930. it is a bolt-in, weld in plates to the frame and then the cage bolts to them. I just have a bolt-in roll bar in the 951.

Quote:
Because good looking motors make more horsepower
not sure about that but my motto is,"it is better to look good than be 1 sec faster lap time...."

Quote:
I've booked a couple DE's so I have committed to be finished
I keep thinking of doing this, but keep encountering issues with parts. machine shop called with concern about the new valve guides being a lot larger than what came out. well checking with the supplier all that is available, incl from Porsche, are the over sized.

I had ordered them and the valves from another supplier when Lindsey Racing were out. so called Mike and turns out they have new valve guides machined to fit unless the head has been damaged and needs the larger one. so now have another set of valve guides on the way. will my head ever get done?

sent the oil pan to the welder to do the baffle and pick up tube support. got the crank scraper installed but not bolted down until I get the pick up tube support bracket back.

my friend continues to make progress on his TB/WP/etc/etc job on his 944



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84 928S, Ruby Red linen/brown interior - preferred DD
87 924S resurrect and gut and another track car...
86 944 turbo my new DE/track car.
78 930 clone project car.
Old 02-19-2020, 05:22 AM
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Got the car back last Thursday. Since then, I've been welding up the cracks in the seat mount, the holes left from the old bolt in roll bar and the holes in the firewall that were used for heat and AC. Starting to put primer on the cage, now.
Eight weeks to go.





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Daily Driver - '78 911SC RoW, Track - '85.1 944
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Wife's - '11 Mini Cooper
Son's - '85.1 944
Old 03-04-2020, 02:35 AM
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good work.

I got the captive nuts welded to the plates for the 911 cage.

almost have my engine rebuild finished, so putting more focus on this until the 951 is back on the road. got a lot of good advice from Mike Lindsey, along with a lot of parts.... he and Dave are great resources for these cars.

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Bob Cox
84 928S, Ruby Red linen/brown interior - preferred DD
87 924S resurrect and gut and another track car...
86 944 turbo my new DE/track car.
78 930 clone project car.
Old 03-05-2020, 05:13 AM
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This past weekend, I finished priming the roll bar and decided to stick to the stock on an interior color scheme. I purchased some metallic brown paint that matches the original vinyl and carpet. That will cover most of the interior. The rear seat area and on back will still get an RS carpet type of treatment. And the roll bar will be Pastel Beige (to match the exterior) with red padding, where needed.

I've abandoned my thoughts of modifying the stock dashboard and ordered a fiberglass unit from GT Racing. I'm thinking about covering it with a brown vinyl. Or maybe I'll paint it...

And since I'm not using the stock dashboard, I picked up a new 4" tach and fuel and coolant temp gauges to replace the stock units, plus some neat little indicator lights.

What I am most proud of, in this weekend's work, is the interior door handle. With the NASCAR bars, the doors had to be gutted and the door handle has to be relocated. I researched how others have addressed this problem. But I was not satisfied with anything I saw. So I did this:

Decided where I wanted it.



Welded in some 18ga steel (crappy welds, I know)



Measured, marked, measured again, drilled and mounted the handle



"Hey, Glenn! Why did you make it stand off so much?" 'Cause I wanted to do this...



By trimming the door panel where I did, I keep a stock-ish appearance to the top of the door and still clear the NASCAR bars. After I run a cable from the handle to the latch, it will be good looking and functional.

7 weeks to go.
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Daily Driver - '78 911SC RoW, Track - '85.1 944
Support vehicle - '00 Suburban 2500 4x4
Wife's - '11 Mini Cooper
Son's - '85.1 944
Old 03-09-2020, 04:37 PM
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I'm still waiting for engine parts to come back from powder coating and plating. And the dashboard won't arrive for several more days.

So, I want to start painting the interior and cage. I just can't decide which to do first, the cage or interior. Anyone have a recommendation?

Also wondering if I should use a detail gun on the cage or regular gun with a narrow fan. Again, anyone have a recommendation?
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Daily Driver - '78 911SC RoW, Track - '85.1 944
Support vehicle - '00 Suburban 2500 4x4
Wife's - '11 Mini Cooper
Son's - '85.1 944
Old 03-19-2020, 03:09 PM
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I'd go detail gun. I use a cheapie gravity feed HF version and one thing you'll appreciate is how light the gun is as you're contorting yourself to hit all the angles and nooks/crannies; a production size gun will be heavy and waste a lot of material. The detail gun will shoot plenty wide enough; I used mine when I painted all my brake stuff: calipers, backing plates and various other stuff. John
Old 03-21-2020, 05:32 PM
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Looks like the company that is plating some of my engine parts has shut down for the pandemic, like so many others. So, the completion of the engine is on hold. I've done what I can, belt rollers, engine mount arms, AOS, and some other little things.



The weather hasn't been what I would like for painting, but today was warm and it wasn't raining. So I rigged a shelter from the wind in my driveway and shot the inside of the doors. I used the small detail gun and it worked very well.
I prepare the doors like I would for a street car and was spraying in less than ideal conditions but I am mostly satisfied with the results. There is one spot on the driver's door where I missed some residue from the silicone that had been used to glue the plastic barrier to the door. I'll have to sand and respray that.



I'm assuming 1 or more of my first planned events will be canceled. Which means I have more time than I originally thought.

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Daily Driver - '78 911SC RoW, Track - '85.1 944
Support vehicle - '00 Suburban 2500 4x4
Wife's - '11 Mini Cooper
Son's - '85.1 944
Old 03-29-2020, 01:13 PM
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