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Carrera "RS-4" build

Hi all

I thought I would share my “RS-4” project, the details of which are below. The donor car was an incredibly clean, straight and rust free 1990 C4.

The skunk works at Auto-haus Hamilton have been entrusted to tackle the majority of the work. Auto-haus have 45 years’ experience in building some of Australia’s toughest circuit, rally and street cars. The car was purchased off another long term customer of theirs, so they knew the history of the car and what needed to be done.

We have taken some ideas (and lessons) from their Group 4 project, as well as the C2 RS, C4 Lightweight, even 918 Spyder, tweaked them and added plenty of our own.

Summary:

Mechanical
Engine blueprinted and balanced
Custom grind cams
Titanium valve springs and retainers
Ported heads
Motec M84 ECU
993 RS valves
Mahle high compression pistons
Rothsport (Jenvey) ITBs and plenum
ARP rod bolts
ARP head studs
Heavy duty clutch
RS flywheel
Semi-solid engine and trans mounts
Fabspeed RSR headers and muffler
Billet rocker covers
GT3 oil pump
Carbon RS heater pipe
Uprated fuel pump

Suspension, Brakes and wheels
Bilstein PSS10 coil overs and rear strut tops
Wheel alignment, corner balance and set ride heights
Brembo 355mm & 328mm brakes with 2 piece rotors
Braided lines
993 steering rack brace
Victor equipment "Zehn" wheels – 18x8 ET45 and 18x9.5 ET49
Pirelli P-Zero tyres - 235/40R18 and 265/35R18

Panel Work/Exterior
993 Cup mirrors
993 door handles
Rolled guards
Respray in GT3 RS Grey Black
“Porsche” side decals
Ducktail
Engine lid hinge adaptors
Replace all rubbers and seals
Clear indicator lenses (front bar)
Brake ducts (front bar)
New tail lights
Rear reflector delete panel
New headlight lenses and HID upgrade
New rear bumper for dual exhaust

Interior
½ cage
Sparco Evo seats
Sparco R-345 steering wheel
Rennline quick release
Rennline pedal pads
Rennline floor boards
Rennline billet gear knob & door locks
Wevo shift coupler
RS door trims
RS carpet
Dash, knee pads, door tops and centre console retrimmed in alcantara
Leather gearshift boot
Carbon fibre console inserts
New sun visors
New headlining
Schroth 6 point harnesses
Extinguisher
Remove soundproofing

Miscellaneous
Oil hoses
Diff seals
Steering rack boots
Drive shaft boots
Replace engine soundproofing
Overhaul air-con
And a few other bits and pieces

Rendering of the finished project. Still to decide on whether the decals will be green or black.

http://i125.photobucket.com/albums/p...s%20Layout.jpg

As delivered:

One could have simply fixed up the miscellaneous bits and pieces, done a top end rebuild to address a broken head stud and driven it quite happily…but we had other ideas.

http://i125.photobucket.com/albums/p...997559_o_1.jpg

http://i125.photobucket.com/albums/p...80220975_o.jpg

http://i125.photobucket.com/albums/p...604_143930.jpg

http://i125.photobucket.com/albums/p...604_144827.jpg

http://i125.photobucket.com/albums/p...604_144844.jpg

Looks like an awesome project, can't wait to see more updates and the completed car!

Why only half a cage? And, more interestingly, are you doing anything to the transmission?

Full cage is a PITA to get in and out of and it is difficult to get registered here. Plus it's a road car after all.

Trans is rebuilt, with new clutch and LWT flywheel.

I'm currently in France on holiday but news from home is that the car is being sprayed this week!

My brother sent me this cheeky pic. Panama green and grey-black

http://i125.photobucket.com/albums/p.../photo%203.jpg

wow nice job so far.

Wow! Can't wait to see how this thing turns out!

Quote:

Originally Posted by billydeakins (Post 8255941)

Wow! Can't wait to see how this thing turns out!

Aiming to have it finished for PCA Concours in November

Throttle boddies, pistons, cams and heads have arrived at the workshop :D

Quick update:

Bit of a holdup with the engine. While we have all the parts, the engine guru has taken a couple of weeks paternity leave (prematurely).

Suspension is in. They had to return one of the shocks to Bilstein as the adjusment mech wasnt working.

Brakes rotors and wheels are on.

Interior is back from the tirmmer and the panels are back from the painter, so we will see some major progress there next week or so.