The past year with my turbo...

[1.2gees]

Bought it as a 944 turbo that needed some work. $2350 (The things that worked were limited to one function of the powerseats, and the power passanger mirror as well as both the power windows. Nothing else electrical worked, nothing!) But the body was straight, and the miles were high (169k?) which is exactly what I wanted. A 944 turbo I could ressurrect, with an accident free and fairly straight body/chasis. As I write this windshield/headlight washers and AC are the only electrical things that don't work. PS is disabled for the time being, I might convert to manual, we shall see. Other than that though, it drove OK, except for the brakes and had massive oil leaks. I decided to do a head job on it, pulled the engine to find 4 bent valves (valve float). Ended up completely re-doing the head, but ofcourse I couldn't stop there.

I rebuilt my engine, (ofcourse with all new belts, seals, rollers, water pump, motor mounts, etc. etc.) and as soon as I started the car (milage was around 173k, the motor had never been apart before) it started leaking antifreeze from the header to head exhaust gaskets (and ran pretty badly). One quick look at the oil showed excessive antifreeze and vice versa. That turned out to be the turbocharger! The center section of the turbocharger was visibly split. It also welded itself to the turbo mount bolts. Being a mechanic helped here (plasma cutter!).

Replaced turbocharger, drove the car home and was greeted to about 3 quarts of oil on the ground after parking it for 2 hours. Oil pan gasket #1 came out. This happened 6 more times. I've checked compression, and leakdown (I had seen the dipstick come up before), both came out very, very good, and even (%2 across the board). I tried so many things for this gasket. The final solution was using a dry gasket, with not a drip of anything, anywhere. Religious following of torqes and sequences, new pan, new pick up. I also increased the capacity of the crankcase vent system. I still suspect the K26 (allowing exhaust pressure to bleed into the crancase). I don't know that for sure, but if that is the case, the turbo shouldn't last much longer anyway. 2600miles far, so good.

During the gaskets, I replaced shocks, some bushings, etc. The entire braking system, some bearings, etc. There's still something loose in the front, I suspect it's the rack, which I bought used, so no hard feelings there. I do need to do something about it soon however.

The car was broken into, my stereo and the beloved infinity speakers/sub stolen. Replaced with a blaupunkt head unit, infinity component speakers, new wiring through out, new antenna amp, etc. I have two 8s that are going to go in when I can make something fit in the rear storage cubbies, that is invisible, and perhaps a little lightweight also.

Overall the car has come a VERY long way. My ac clutch is also going out. I have about $6500 into the car including purchase (and there's about a zillion things I didn't mention like custom turbo back exhaust, short shifter, a rebuilt/shimmed wastegate, guru chips, intake, boost controller, SS brake lines, upgraded master cylinder, roll bar, etc. etc.), so I don't feel too bad. Hopefully I'll start tracking it soon. Maybe even a set of coil overs a big turbo, MAP, injectors... Needless to say, I have done all of the work to the car, except when I was pressed for time, had a few buddies help with minor stuff (change the oil while I'm aligning the car forexample, or bleed the brakes while I'm doing the oil pan gaskets!). Aside from paying for things like fuel pressure regulators or chips, I made/fabricated/modified everything myself.

This is also while I go to school with more than a full time student's load (currently @NCSU) and until 3 weeks ago a part time job as a mechanic as well. The latter helped with keeping the costs down.

OK, time to play the student part again, back to my second to last political science paper...
Ahmet

[ronin]

Did you take any before-and-after photos during the process? Soon, I myself will be starting the rejuvenation process on my 951. I'd love to be able to see how others have dealt with repairs and restoration on their cars. It can potentially save a lot of time and grief.

Polisci eh? Me too

[1.2gees]

I did take several pictures, and saved them to my p-car online profile. The week that I formatted my hard drive, theirs crashed. Causing me to permanently loose all pictures of the rebuild, save for one picture of the head after all the p&p work, new valves, seals, etc.
Ahmet

[1.2gees]

1.2gees
Moderator

Registered: Mar 2000
Location: Cary NC United States
Posts: 3054

And this is all the love I get from you?

Well then here's to all of you
Ahmet

[ronin]

LOL, that is just too funny. And you know damned well that quite a few people looked at this post!

[1.2gees]

Yes, yes they have...
Ahmet

[ronin]

did you see lately??? 121 views and still no additional posts! Ingrates!!

[Sam Lin]

Cool project! More posts!

Sam

[scottmandue]

We are all just jealous

[mideastmafia]

Here is something for your efforts Mr. Ahmet..




SHAUN

[1.2gees]

I sheared off some cv joint bolts off today...

Thankfully I had some tools with me and 4 of them were still intact.

This much power man, it's a trip. At least I haven't broken any transaxles yet!
Ahmet

[ronin]

now, you didn't mention how much power you're making. it's gotta be quite a bit to be shearing off CV bolts!!

[1.2gees]

I think I'm making 260hp w/around 300ft-lbs, which isn't too bad, however it's not outragous either. There are 944 turbos w/a whole lot more power than my car, but most of them don't have nearly 200k though.

As cool as it would be if I broke those bolts off because of too much power, I think there's something else going on. I think some of the other bolts may have worked their way loose, and the two that were tight just broke off. Hopefully it won't be too hard of a fix.
Ahmet

[mideastmafia]

What is with you and drivertrains in cars Ahmtet?

Didn't you go thru about 10 transaxles in the NA and now this with the turbo? Maybe your not driving it right.


SHAUN

[ronin]

wow, a driving style that breaks CVs. now THAT'S unique

[1.2gees]

Yeah, I don't think I did anything special to break those bolts off. It's a somewhat common problem like I said before.

Chanses are some of the bolts loosened, and the ones that didn't couldn't hold the torque by themselves. I put the reamining 4 back in (vise grip tight, on the side of the road), and it got me home, about 35 miles away...
Ahmet

[ronin]

getting those broken studs out after you got home must have been a b#tch though

[1.2gees]

Actually I don't know yet, I will take it to the shop tomorrow morning and find out... I did find some stronger bolts, which should help out a great deal, in avoiding future problems...
Ahmet

[ronin]

Two words, Cee Four

[SoCal Driver]

Love shaped charges! Surprising what a little mud can do!