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-   -   86 carrera LS1 swap (http://forums.pelicanparts.com/porsche-engine-conversion-tech-forum/1052886-86-carrera-ls1-swap.html)

VacantSky 11-19-2020 03:37 PM

Quote:

Originally Posted by Yan2947 (Post 11109195)
Vacantsky, do you have a photo of your radiator hose going to the front as it passes the cross member? Your return is opposite side mirrored?

I can get a fresh one for you but it won’t be until this weekend, for now if you look back at post 58 you can see the crossmember and the hose passes through it, when it exits the other side it hugs the fuel tank opening. You can see the hole cut for the return side where I hadn’t plumbed that hose yet. I kind of borrowed the idea from the “RSR LS conversion” thread. Page 10 you can see he has the coolant lines route through the crossmember! I used a 1.5” hole saw. And sanded the bore smooth to play nice with the hose.

dtakenname 11-19-2020 04:13 PM

Hope to see some videos of the car too,

Yan2947 11-20-2020 04:48 AM

Vacantsky, I see the hole now. If you do get a chance to photo the crossmember and the and how it hugs the fuel tank and goes from there to the radiator. Look great. I really like where you mounted the water pump. Out of the way! You used a regular 1.5" metal hole saw blade? or a stepped dril bit?
Thanks,
Yan

kach22i 11-24-2020 05:03 AM

Quote:

Originally Posted by VacantSky (Post 11103313)
Spoiler alert on the wheels.. Heritage 6 by MOMO.. F: 17x8.5 et30, R: 17x10 et20.

Nice project.

First time I've seen someone using the Momo wheels, they look great. Wish they did a 5-spoke in 15 or 16 inch.

Pedal cluster modification, it took me weeks and weeks to refurbish mine, I cannot even imagine trying to modify one.

Kudos.

VacantSky 12-04-2020 09:46 AM

Quote:

Originally Posted by kach22i (Post 11115356)
Nice project.

First time I've seen someone using the Momo wheels, they look great. Wish they did a 5-spoke in 15 or 16 inch.

Pedal cluster modification, it took me weeks and weeks to refurbish mine, I cannot even imagine trying to modify one.

Kudos.

Thanks! I love these wheels, looks like I got one of the last “custom” sets as Momo offers these in off the shelf sizes (With only two color options now) for certain applications, the 911 ones would be 17x8/9.5 only. I know they made a 1 off 5 spoke set for a Rod Emory 356 build, and they look great! Personally I love the 6 spoke over the traditional 5.

The pedal wasn’t too bad, it was a tougher decision to make but I think it will pay off in the long run with the NLA 930 part!

Quote:

Originally Posted by Yan2947 (Post 11110572)
Vacantsky, I see the hole now. If you do get a chance to photo the crossmember and the and how it hugs the fuel tank and goes from there to the radiator. Look great. I really like where you mounted the water pump. Out of the way! You used a regular 1.5" metal hole saw blade? or a stepped dril bit?
Thanks,
Yan

Yan, this took longer than I said so I apologize but here is the picture of the coolant hoses up front. No pic to the radiator as it is removed so I can close up the hole but you can see where they pass to get there. Bought some sheet metal this week so hopefully will have this closed up soon. I’ve been busy rebuilding brake lines and addressing the brakes. Rabbit holes that slow me down as per usual! To cut the holes I used a 1.5” hole saw after drilling a pilot hole. Where they cross over near the fwd control arm bushings I’ll use one more adel clamp per side to hold them in place

http://forums.pelicanparts.com/uploa...1607107231.jpg

Yan2947 12-05-2020 08:50 AM

Looks great and I really appreciate the photo because it shows exactly what a good build with the radiator in the front needs. Did you use one length hose for each side or did you have some cuts where it goes through the cross beam with silicone angled hoses? You used one and a half inch hose the whole way or inch and a quarter in each direction? Thanks again for the photo Perfect!

VacantSky 12-05-2020 12:06 PM

Quote:

Originally Posted by Yan2947 (Post 11129586)
Looks great and I really appreciate the photo because it shows exactly what a good build with the radiator in the front needs. Did you use one length hose for each side or did you have some cuts where it goes through the cross beam with silicone angled hoses? You used one and a half inch hose the whole way or inch and a quarter in each direction? Thanks again for the photo Perfect!

No problem! I’m keen to document as much swap specific stuff I did as possible or take specific photos so anyone else in the future can have a thread to bounce ideas out of, or just copy! Could save someone some time!

The hose is 1-1/4” ID to and from (I believe that’s how both renegade & toy-jet do it too) and it’s pretty much one piece per side, the only cuts are to accommodate a couple T fittings for the expansion tank lines, the water pump, and of course a thermostat (I’m using a mezeir 170)

Here are a couple more pics to show the rest of the coolant system, I used a formed 45 off the right side of the engine just because the other hose would have kinked a little more than I would have liked to get the angle I desired. It shows a T fitting between the engine and water pump (hidden by the expansion tank). The steam port will be connected to the small inlet on top of the tank.

http://forums.pelicanparts.com/uploa...1607201041.jpg

The second picture is my left rear wheel well showing the thermostat housing and the second T that links to the expansion tank. (The 3/8 line jumps over the top of the transmission to the tank)

http://forums.pelicanparts.com/uploa...1607201041.jpg

The third pic is the T fittings I am using (from a VW pt# 1C0121087E) and are 1-1/4” OD in/out with a 3/8” OD T for the lines to run to the expansion tank. The C5 corvette tank has two lines coming out of it, otherwise 1 T would have been fine. If anyone else does something similar with a 2 port expansion tank make sure your second T is AFTER the thermostat so the tank isn’t used as a bypass while the Thermostat is closed. I don’t think it would be a problem, but I didn’t want to find out either. For now I have “no bypass” but I drilled two 1/4” holes in my thermostat to allow coolant to pass through and not create hot spots in the engine while it warms up, or dead head the pump.

http://forums.pelicanparts.com/uploa...1607201041.jpg

Pro(?) tip, USE AMAZON PRIME! If I can find a part I want to try out, but am unsure of it’s compatibility and it’s available on prime that’s how I buy it. Even if it’s cheaper elsewhere, the return policy is incredible: no questions asked. If you don’t want it start the return and drop it off with UPS. Done. Refunded. I’ve had so many things in and out of the garage through prime to help figure things out, it’s been a life saver!

VacantSky 02-23-2021 05:19 PM

Really dragging my feet here guys sorry. I have a wife with a nursing career and we have a two year old so the swap project gets neglected from time to time. Plus I want all the supporting stuff to be taken care of too, so with that being said I finished my 993 caliper conversion over 930 rotors today. Tomorrow (once UPS shows up with it) I’m working on my shroud to close up the hole in the front tub. Ordered a 36x36 sheet of aluminum from McMaster Carr to fab it from. Plan is to affix it with fasteners so it can be removed to service the fans from above if need be. I rolled her out today after being on jacks for a couple months for a wash and with the front bumper on you can see how the RUF valance will feed the radiator nicely.

http://forums.pelicanparts.com/uploa...1614132403.jpg
http://forums.pelicanparts.com/uploa...1614132403.jpg
http://forums.pelicanparts.com/uploa...1614132403.jpg
http://forums.pelicanparts.com/uploa...1614132403.jpg

Valance will be painted shortly, and the screws will be painted along with it. Originally it’s supposed to 3M tape to the lower lip of the bumper but I wasn’t a fan of it, and obviously I’m not afraid of modifying the car so screws it is lol

Hopefully have a better update soon!

Yan2947 02-25-2021 04:59 AM

With my 86 can you tell me what I would need to do brakes like what you did.? Was it simple bolt on bolt off and do you know what parts are needed. What you were doing looks phenomenal!

VacantSky 02-26-2021 09:15 AM

Quote:

Originally Posted by Yan2947 (Post 11239105)
With my 86 can you tell me what I would need to do brakes like what you did.? Was it simple bolt on bolt off and do you know what parts are needed. What you were doing looks phenomenal!

Yan, the fronts are fairly straight forward. Patrick motorsports 993tt caliper adapters (these work with C2/C4 calipers and appropriate sized rotor which is what I’m using) a set of rebel racing rotor hats and some wilwood 12.19x1.25 HD rotors (you could use 11.75x1.25 to avoid the next step). I had to shim the caliper outward because the rotor is a 309mm vs the 304mm the C2/4 uses. Some grade 8 washers took care of that. Also I had to shim the adaptor ever so slightly to center the caliper on the rotor

The rear is a little more tricky, it is documented on these forums if you search “993 rear caliper mods pelican” on google. The rears usually accept a 299x24 so you have to widen the caliper throat a little bit, there are some casting bulges and the pad guides interfere with the rotor. And then the mounting holes need to be filled and redrilled, I used aluminum all thread and red loctite to fill the 3.75” spaced holes and redrilled them to 3”. The measurement to drill down from the padbox is 12.5mm with the holes 3” on center. Again all of that stuff is well documented on here. Then you just use a stock set of 930 rear rotors which slip right on (309x28). Some say you have to shave the pads too, but I found that stop tech pads fit (just)

I like the 12.19 rotors on the front because it makes all four rotors the same diameter.
There are easier solutions, such as the 996 conversion which is truly bolt on and uses all oem parts (after the adaptors of course) but the brake bias is a little front heavy compared to the 993 C2/4 calipers. The 993 give you a F/R braking ratio of 1.56 which is considered by many perfect for pre ABS air cooled cars.

I think all in I did front and rear for under $1400

Yan2947 02-27-2021 04:47 AM

Thank you. Will read up on it all. Great build!

creaturecat 03-01-2021 03:41 PM

looking good!

dtakenname 04-04-2021 07:54 AM

Hi,
So are you happy with engine operating temperature?
Any updates?

VacantSky 05-09-2021 06:59 PM

Been a while since I’ve updated. Still not running.. been dealing with a lot of medical issues in the military and preparing to possibly be medically discharged so the car has taken the back burner again.. but should be running before the month is out! Finally closed up the hole in the front and mounted the radiator for (hopefully) the last time. This was trickier than I thought using hand tools in the garage but with a $70 bending brake from harbor freight and some 16ga aluminum I made a duct. It’s bonded and fastened to the car. I may revisit down the road and weld in some steel, but it should be just fine and may just stay this way.

http://forums.pelicanparts.com/uploa...1620614054.jpg

The sealer was still drying in this pic, but the back sides of the fasteners will be cut flush and I’ll likely paint it black in the frunk area. You can also see one of my rabbit holes in this pic, my restored fuel tank.. I’m a sucker for “while your in there”

http://forums.pelicanparts.com/uploa...1620614054.jpg

Exhaust is up this week, just need to cut and tack a few pieces together and take them to a Shop that can TIG. The rear section is actually an after market piece for a 996tt. I really wanted the X-pipe to get the benefits of the scavenging effect from both banks, and to smooth out the tone so it doesn’t sound like a clapped out Silverado.. It’ll have twin exit 2.5” tail pipes going through the bumper where the pads used to live.

http://forums.pelicanparts.com/uploa...1620614535.jpg

It’s mounted to the cradle using some high tensile 6-1/4” bolts and some 4” stand offs, leaving about 1-1/8” space between it and the crank pulley. I’ll likely make a heat shield to be careful.
http://forums.pelicanparts.com/uploa...1620614535.jpg

Here the turbo mount flange will be cut off and 2 90’s will be welded to it and to the header mount flange (rough idea)

http://forums.pelicanparts.com/uploa...1620614535.jpg
http://forums.pelicanparts.com/uploa...1620614535.jpg

Really hoping I have a video soon!

Here’s a head on view with the RUF CTR replica valance. Will feed the rad perfectly. She’s filthy I know.. Florida pollen..
http://forums.pelicanparts.com/uploa...1620615207.jpg

And here you can spy my air conditioning! AKA 65-68 901 swing vent windows, retrofitted to my aluminum frames.

http://forums.pelicanparts.com/uploa...1620615207.jpg

VacantSky 05-10-2021 05:26 PM

Fiddled with the driver side exhaust today. Will adjust the fit-up a little but here is how it will look, tomorrow I’ll size up the passenger side and tack it together:

http://forums.pelicanparts.com/uploa...1620696334.jpg

Ryan_Cunningham 05-10-2021 05:56 PM

Looks great! Looking forward to seeing some video.

VacantSky 05-13-2021 05:51 PM

Quote:

Originally Posted by Ryan_Cunningham (Post 11327576)
Looks great! Looking forward to seeing some video.

Thanks!

Got the L&R exhaust pieces welded at a local fabricator and mounted, going to have a muffler shop expand my 2.5” 90’s I’m using as tips so I can slip joint them on and have room for adjustment.

http://forums.pelicanparts.com/uploa...1620956755.jpg
http://forums.pelicanparts.com/uploa...1620956755.jpg

Filled her up with fresh oil, trans fluid, and coolant (blasphemy) yesterday. Only to find I have a leak in the cooling system at the water pump adaptor so I removed the fittings from it and re-sealed it. I used Teflon before, but this time I used my favorite RTV: permatex the right stuff. No leaks now :D

Unfortunately the Holley Terminator X doesn’t have my injectors preloaded onto it, and they’re a 1 or 2 year only lower output (read: unpopular) injector so uploading the flow rates etc into the ECU is not worth the time consumed so I just ordered some brand new 30lb/hr injectors. Should be here Tuesday. So, I might have it fired up next week!

Also: here’s how my frunk looks, just as usable as it was with the AC and tool kit/jack installed! The fresh air blower is currently out, but will be put back in

http://forums.pelicanparts.com/uploa...1620956997.jpg

Ryan_Cunningham 05-16-2021 03:13 PM

Incredibly jealous of how clean everything looks. Can't wait for more!

VacantSky 05-17-2021 08:10 AM

Quote:

Originally Posted by Ryan_Cunningham (Post 11333833)
Incredibly jealous of how clean everything looks. Can't wait for more!

Thanks man! The frunk picture does it more justice than in person lol. But if you mean the build in general I appreciate it, I could nitpick it all day (I think I could with anything) so it’s reassuring to hear someone else say it!

Gave her a bath yesterday. Injectors should be here today

http://forums.pelicanparts.com/uploa...1621267724.jpg

http://forums.pelicanparts.com/uploa...1621267724.jpg

VacantSky 05-18-2021 05:16 PM

She lives! Not sure how to embed..

https://youtu.be/3dhgOh8HdLg

https://youtu.be/kaz5q46Rv8o

^Second and third startups

First start up was immediate and hard, it was absolutely fulfilling lol. Then fuel started spraying everywhere and I shut her down. Wish I had the fire off on video. Had to be timid with revving as the Holley needs the time to learn so hopefully over the next week I’ll have a safe base tune dialed in and can get her on the road!

Next up after that is an alignment. She needs it!


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