Project 964 Trackcar

[964uk]

Hi everyone,

I have been using this forum for a while now (plenty of reading with only a handful of posts), I have been impressed with the knowledge base here, and the encouragement given to those with project builds underway.

I have decided to document the build of my latest project, a 964 trackcar. The intention is for the car to be road legal, but heavily track focussed, weld in cage, perpex windows, etc. This certainly will not be a ‘trailer queen’, the intention is to use regularly at UK circuits, plus the occasional trip to the Nurburgring.

The inspiration for the build will be the 964 Cup cars from the early 90’s, although this will have to be completed for a fraction of their current price.

I recently bought a pair of 964’s, although this sounds flash, it actually consisted of a bare shell (1989 manufacture), see photos below, and a complete late ’92 964 Carerra 2 minus the roof, a tree fell on it whilst parked.









Basic planned spec is as follows:-

6 point CDS roll cage with double door bars
Seam welding, as per Porsche Workshop Manual for RS
Underseal and sound deadening removed
Sunroof panel welded in place and lead filled
Perpex windows
KW Variant 3 Suspension
Porsche ‘Big Red’ brakes with drilled disks
RS Anti-roll bars/ drop links (or alternative)
Standard 3.6 motor with modified air intake and remap (275 bhp?)
Single race seat with Harness
Fire extinguisher, ignition and FE released internal/ external
Dry weight approx 1100Kg (fingers crossed)

The time available for me to work on the car is fairly limited at the moment, therefore progress may start slowly. I collected the car from storage yesterday, it now sits in my rather messy garage (time to tidy I think)!! The car will be built by myself, with a little help from a few friends along the way. Having been without a 911 for 6 years now, I cannot wait to get started.

Thanks,

Andy

[Oh Haha]

Cool project.

You should post in the 911 tech forum too as alot of the build can be done to the pre 89 cars.

Plus we ALL love 911 builds.

[Kevin Stewart]

Lets get at it man, seriously should be a good read, Kevin

[964uk]

Thanks.

Are we allowed to double post on here, i.e. 964 Tech Forum and 911 Tech Forum?

[Bill Verburg]

Sound like a great project.

You going to use the /4 or /2 booster & M/C?

[964uk]

Bill - The intention was to use the standard C2 setup, although the ABS Pump/ booster is one part that is missing from the donor car.

What would you recommend? Any advise would be much appreciated.

[Don Plumley]

Nice project!

[earlyapex]

I recommend that you contact Geoffry Ring. He built a beautiful 3.8L 964 and has posted much this on Rennlist.

http://www.racetek-engineering.com/

Tom Weber has built a beautiful 964 based GTL race car. You can do a search on Pelican for threads on his build.

[964uk]

Geoffry's car is fantastic........a real inspiration!!

[Bill Verburg]

Originally Posted by 964uk

Bill - The intention was to use the standard C2 setup, although the ABS Pump/ booster is one part that is missing from the donor car.

What would you recommend? Any advise would be much appreciated.

I'd prefer the electro-hyd setup from the C4, If you are installing something like 964RS brakes on the car you will want either 993 vacuum boosted m/c or the C4 set up

You will also want 993 front struts and RS uprights(but even stock 993 uprights will be better than any of the 964 parts).

[964uk]

Bill - Thanks for the advice, I will no doubt be asking more questions!! Not really considered 993 parts, I assume some will be an improvement over the 964?

I am not that well versed on the various Porsche braking systems. I have just sold my Golf MK2 Race car, that ran 239mm discs on the front with single pot calipers, anything will be better than that!!

[Bill Verburg]

Originally Posted by 964uk

Bill - Thanks for the advice, I will no doubt be asking more questions!! Not really considered 993 parts, I assume some will be an improvement over the 964?

I am not that well versed on the various Porsche braking systems. I have just sold my Golf MK2 Race car, that ran 239mm discs on the front with single pot calipers, anything will be better than that!!

Given your stated desire to include

Porsche ‘Big Red’ brakes with drilled disks

the best course is to use either 993 vacuum booster and m/c or the 964C4 electro- hydraulic boost system, either allows the use of a 23.8mm m/c which is the minimum size for RS brakes, the electro hyd system further allows for a 25.4mm m/c which is even better.

To use Big Reds on a 964 it is best to use as many 993 parts as possible,
if you use 993 strutsand 993 uprights(or better 993RS uprights) then 993 Big Red calipers and rotors are a straight bolt on. There is also a black version which will match the black 993 rear calipers that you need to use w/ the Big fronts. To use the 993 uprights you will need to use 993 tie rods, 993RS uprights will require the use of 993RS or GT2 evo tierods. But all the 964 stuff is a straight bolt on

In back use 993 rear calipers and stock 964 rotors or if you want drilled 951 M030 rear rotors

[964uk]

Bill - Thanks for the information.

[964uk]

Finally managed to get some garage time today. First job was to strip out the old wiring loom and air conditioning/ blower unit. This is all surplus to requirements as the donor car has a complete loom, and a light weight blower unit will be used.




Next I started removal of the sunroof cassette, then closing of the opening. Ideally this would have been a new skin, but I would rather use the money saved on upgrading the suspension and brakes!! Removal of the sunroof sleeve was easier than expected as a majority of it was bonded in.




Then closing of the sunroof opening. We used mig for this, on a very low power setting, initially we spent about an hour getting the alignment of the panel right. There was some distortion but nothing that we cannot take out with a dolly and light skim of filler. Really pleased with the progress.





Next job is to grind back, complete dressing the underside, as some of the sleeve was left in place for support whilst welding. Then the cage install can commence!!

Has anyone had any joy with using lead to fill?

Until next time,

Andy

[Kevin Stewart]

fiberglass will be lighter, Kevin

[SAM DACOSTA]

Originally Posted by Kevin Stewart

fiberglass will be lighter, Kevin

This is going to be a good thread. I wondered the same thing when I read his last post about using lead to fill, then I thought maybe it was used for structural integrity. Let's wait on his comment as to why he's lead filling over fiberglass?

[964uk]

My concern with using filler was the potential for cracking/ sinking in years to come, although I will get away with a very light skim of filler once the mig weld has been ground back.

Point taken regarding the weight, although there would only be a very small amount of lead used.

[Kevin Stewart]

seeing how you are going to track the car i think cracking bondle will be the least of your worries. I would weld grind etc then light glass work. Kevin

[964uk]

Kevin - Good point!!

[Kevin Stewart]

if you are putting a full cage in it how about use a fiberglass insert? i mean it goes from window to window should be able to loose weight, Kevin