Preparation of 951 rebuild project

arnebret · 03-22-2004, 01:59 AM

Hi guys,

First a confession:
It's been a long time since i last visited this forum, I have been pretty selfish... After all the tips from you guys I got my 88 Turbo running and since then it has resulted in nothing but fun. I have to confess: I left out on the forum when my car was starting to run reliable... i'm VERY sorry and i'm planning to help other people with their questions more actively.

As I said the car has been great over the past year or so, but I’m planning to do a ‘rebuild’ project on the car. As I’m currently studying Automotive Engineering and I just like working on my Porsche, I decided to do things right this summer:

I’m planning to take the car off the street and into the garage for some months and do whatever I can to restore it. The focus will be on the mechanical stuff, currently I’m not thinking about a complete repaint. The main problem will be: funds… as ever.

So, before starting the project (somewhere in may or june) I want to make up a decent plan. So, I’m asking you guys:

WHAT TO DO?? Or maybe: what NOT to do…

I’m thinking of a complete strip down and inspection of all parts. Of course I will be replacing all the rubbers, hoses, bearings etc. I will also clean up all the parts that are still useable. Also stuff like the generator will go out for a professional inspection and if necessary a rebuild. So let me point out: it will not be a ten thousands costing complete rebuild of the complete car. I will focus on the important stuff to make the car last another 100k miles, at least.

For example: I’m planning to do a complete inspection of the engine and replace all the stuff like piston rings, gaskets, bearings etc. I’m not planning for a complete rebuild of the head or a new bore in the block.

The main target is: getting a very reliable, high quality 944 Turbo. It does NOT have to be completely stock and autoshow ready.

Coming back on the ‘non-stock’ thing: how about upgrades? I already have a great ECU chip, but what are some other must-do upgrades?

I hope you guys can supply with some useful info and tips concerning the rebuild so I can make this project a success and put a Porsche worthy 951 back on the road.

Thanks in advance!

Wolf1 · 03-22-2004, 05:37 AM

Quote:

Originally posted by arnebret
Hi guys,
I’m not planning for a complete rebuild of the head

Coming back on the ‘non-stock’ thing: how about upgrades? I already have a great ECU chip, but what are some other must-do upgrades?

Thanks in advance!

I would definately have the head rebuilt!!! It won't cost much more for a basic valve job and could help prevent problems in the future.

A MAF conversion would be nice, as well as a larger turbo...

arnebret · 05:52 AM

Ok, taking it into consideration. I'll have to check what the local companies charge for a job like that. But, come to think of it, replacing the valves and valveseats might indeed prevent a lot of typical 'worn' engine symptoms.

A MAF would indeed be very nice, but is pretty expensive considering what you get back for it. Also, a larger turbo will increase the turbo lag and will only result in more torque and power at high loads. I'm not really looking for that at the moment.

Thanks for the input!

ae1969 · 03-22-2004, 11:10 AM

NIce to see you back......

Considering I am on my second full rebuild...........

This will cost you close to 10K on the turbo. If you want to walk away with a huge grin on your face!

1. Seals, rollers, bearings, rings,waterpump, hoses, and odds and ends assuming the car is within spec and no machining is needed on the bottom end will cost you 1500-2000

2. Clutch pack - Stock 600-800

Upgrades - Aluminum flywheel 300, KEP pressure plate 600, Cup disc 300

3. Turbo - Stock rebuild 250-350

Upgrades (MAF/TURBO/CHIPS/ Larger injectors, Adj FPR) - 2000-3000

4. Tranny - If you go for bigger horsepower you will need LSD. The regular tranny just doesnt let you hook the power up.
Upgrades - LSD tranny - 1000-1400

5. Exhaust - Stock- Replace all crush rings

Upgrades
- Testpipe - 250-500 (depending if you go 2.5 or 3 inch)
- cat back 300-500 (depending what you are looking for)

6. brakes stock (rotors/pads/bearings) - 150-250 per wheel

Upgrades - Big Reds (1000 for the front)

.....and a few other incidentals...

Have fun!

arnebret · 03-22-2004, 11:21 AM

Nice one there!

I really overlooked the LSD. I'm currently a bit scary to put on the power in a corner with my regular tranny as the inside wheel will start slipping pretty soon. I once drove a LSD version, which allowed me to get that power to the wheels a lot quicker.

I'll try if i can swap my current tranny in for a second hand LSD version at my local Porsche shop. Still, this one should be inspected for any wear on the synchro's etc.

All the other stuff is still on my mind, but i'll have to make some choices. I'll probably get my turbo rebuilded, i have no idea in what condition it is at the moment.

Thanks for the input!

ae1969 · 03-22-2004, 11:24 AM

If you stay stock......

Go with www.gururacing.net ...

Chip,wastegate,reliaboost combo.....

He has a new 18 psi chipset for the stock cars. Thats the best bang for your 'Stock' buck

ae1969 · 03-22-2004, 11:40 AM

No don't get MAP upgrade unless you are planning on upgrading your turbo to a larger one....

Email danno and ask him about the 18psi chipset (just chips, boost enhancer) for your year of car and add his wastegate it is one of the cheapest upgrades......

arnebret · 11:44 AM

How did you put the engine back together after the rebuild? For example: how did you do the camshaft and timing of the whole distribution. And for example: do you have the notorious belt tool for the distribution. It might already be a few steps to far, but i reckon these will give me some trouble.

PS: Scuse me for deleting the other post, but i noticed that the MAP upgrade wasn't what you meant and is probably a bit OT. But anyhow, i already have a very fine chip and hardware by a US based tuner. I completly forgot his name, but i paid about 200 bucks or so and it's just an amazing chip with excellent reliabilty for the street.

ae1969 · 12:45 PM

hehehe....

Timing is easy once you have done it a few times.... yup I use P9201 for the tensioning.... it has paid for itself 10 times over!

The biggest problem will be seized/broken bolts (water pump bolts, studs, 2 head bolts by the coolant passage etc)... the turbo exhaust side is a pain in the ass.......

Just make sure you have the factory manuals, haynes, pet cd to guide you. It takes a good 6 months to strip everything down and back up...... (includes waiting for parts)

arnebret · 03-22-2004, 12:48 PM

Fortunatley i have all three of the resources you pointed out. Still, i'm pretty worried about the timing and belt stuff, maybe get some help from my Porsche pro will do the trick..