Young man's first Porsche aka project 951

[os951]

Came just from friend's workshop. Went there to see how our project's new parts manufacturing get along. New shifter was more or less ready.Friend made several other ones for some other people as well.Nice feature is the possibility to use original Porsche parts with this short shifter

Our new transmission carrier was still under manufacturing process

Mazda RX7 oil cooler modified to fit 951

My friend was just changing oil pan gasket for a friend of his 951. He built this support to be able to remove crossmember

 

[os951]

Sifter is ready. Turned out very nicely []

 

[os951]

Black is Beautiful [] From this

To this

We also removed rear side windows to be sure to get black color decently every spot

 

[944Turbo]

Looking very good, Tony

 

[os951]

A package from Alasdair is here []

 

[os951]

Since project car missed some smaller items like engine,my son bought M44/52,complete clutch, powersteering pump, alternator & AC-compressor. No turbo & intake, since we have some plans for those. Thanks to Alasdair for the great deal []

Engine is taken from this wrecked '89 951 which look quite good....

New parts proceed nicely. My friend have almost finished CF 951 strut brace. Weight is almost zero, but it felt very strong. Some final adjustment to design and son's strut brace is ready to bolt on Here's phone pictures which are not good quality

He also fabricated some hubs to early 911 for another friend. This hub allowes to bolt on newer bigger Porsche rotors to old ET 911's without any difficulties with wheels, so no spacers or what so ever won't be needed. You can use Big Reds, 6-pot Monoblocks etc. with this hub. Also old ET 951 version will be here soon. So cheaper Porsche rotors without hat's can be used with old ET 951 as well.These hubs will be machined a bit, to reduce weight.Also anoized process is planned as well for extra strenght.

He will make hubs for son's project as well

 

[DivineE]

Amazing work. I have a few questions for a man with such in-depth knowledge. I have big reds at the moment on WUF. Firstly is there a different brake master cylinder that can be fitted to the 944t to reduce pedal travel with this set up? Second do you know of any lighter brake disks or callipers that can be used? The big reds seem massively heavy?

 

[os951]

Usually oem mastercylinder works just fine. If you would like to use something bigger you can use BMW 700-series unit (late 80's early '90's) Also you can make "combo" what comes to calipers; 911 versions use slightly different pistons which are shorter, so there will be more fluid in caliper cylinders. Most bigger calipers are heavy; Monoblock 6-pots are lighter.4-pot version is even lighter, but smaller what comes to size. Lighter disk means usually use of separte hats (floting disk) which can be made quite light.Unfortunately this is more expensive solution.

 

[barks944]

Do you ever rebuild 951 steering racks Olli, mine has some play in it which looks to be from the rack and pinion. Maybe the pinion is worn, can it easily be replaced?

 

[DivineE]

ORIGINAL: os951 Usually oem mastercylinder works just fine. If you would like to use something bigger you can use BMW 700-series unit (late 80's early '90's) Also you can make "combo" what comes to calipers; 911 versions use slightly different pistons which are shorter, so there will be more fluid in caliper cylinders. Most bigger calipers are heavy; Monoblock 6-pots are lighter.4-pot version is even lighter, but smaller what comes to size. Lighter disk means usually use of separte hats (floting disk) which can be made quite light.Unfortunately this is more expensive solution.

many thanks, very useful information. The 7 series master cylinder and floating disks option sounds good Like you say the regular cylinder works fine but its like a go cart, you have to really work the pedal. I prefer my cars to feel a bit more responsive on the controls.

 

[os951]

Do you ever rebuild 951 steering racks Olli, mine has some play in it which looks to be from the rack and pinion. Maybe the pinion is worn, can it easily be replaced?

Yes i have. Not difficult to do, just messy. Usually rack/pinion does not worn. In some cases when seals have been broken it's possible dirt has gone inside and ruined these parts. If so, get another rack.

 

[os951]

My son check out the condition of cylinder wall's. All 4 cylinders looked like new []

 

[barks944]

I was very impressed by the wear rate of the bored on my 951. 140K and barely any wear, just enough to catch a finger nail on (in technical terms).

 

[DivineE]

Does anyone know the typical thickness of the silicone layer in the bores? I.e how much they can wear before they have to be re-bored?

 

[sawood12]

There are some machining limits in the workshop manual but they are very tight, basically you'd be very lucky to get away with being able to re-bore. The silicon coating is not really a coating at all. It is part of the blocks parent material, which is an aluminium alloy that has a high content of silicone and the silicone exists in relatively large 'globules' within the alloys microstructure. The bores are chemically treated (acid etched) after machining to expose the silicone globules so the bore surfaces are basically 100% silicon - which is about the hardest material known to man - this is why if the bores are not damaged they basically don't wear at all. The problem is it is extremely thin, hence the chances are if you ingest any debris into the cylinders that scores the bores then you are unlikely to be able to re-bore without the need for re-etching the bores after machining. The problem is that there are not that many places left that can acid etch alusil these days.

 

[944 man]

ORIGINAL: DivineE

ORIGINAL: os951 Usually oem mastercylinder works just fine. If you would like to use something bigger you can use BMW 700-series unit (late 80's early '90's) Also you can make "combo" what comes to calipers; 911 versions use slightly different pistons which are shorter, so there will be more fluid in caliper cylinders. Most bigger calipers are heavy; Monoblock 6-pots are lighter.4-pot version is even lighter, but smaller what comes to size. Lighter disk means usually use of separte hats (floting disk) which can be made quite light.Unfortunately this is more expensive solution.

many thanks, very useful information. The 7 series master cylinder and floating disks option sounds good Like you say the regular cylinder works fine but its like a go cart, you have to really work the pedal. I prefer my cars to feel a bit more responsive on the controls.

If you want floating discs, then Id recommend Ian Godney @ Godspeed Racing. They could be a good deal cheaper than you expect. Simon

 

[kenparker]

All this 944 happy corner, is getting me interested in another car. I note Mark over the road from me has just bought a 944 cab for his wife. I had a good look round it the other day it's a very nice car and drives well. I think my wife might end up with my Boxster. I can’t keep up with his collection. So I understand the S2 is the one to look for, but the older cars I am guessing are just as good? I like the idea of a restoration but really would not have the skills needed. Following this in my arm chair and a coffee is going to be as close as I get to spanners. Very nice to follow.

 

[DivineE]

ORIGINAL: sawood12 There are some machining limits in the workshop manual but they are very tight, basically you'd be very lucky to get away with being able to re-bore. The silicon coating is not really a coating at all. It is part of the blocks parent material, which is an aluminium alloy that has a high content of silicone and the silicone exists in relatively large 'globules' within the alloys microstructure. The bores are chemically treated (acid etched) after machining to expose the silicone globules so the bore surfaces are basically 100% silicon - which is about the hardest material known to man - this is why if the bores are not damaged they basically don't wear at all. The problem is it is extremely thin, hence the chances are if you ingest any debris into the cylinders that scores the bores then you are unlikely to be able to re-bore without the need for re-etching the bores after machining. The problem is that there are not that many places left that can acid etch alusil these days.

Serdi in london can still do it. I've used their service and they are very good but you have to buy a set of .5 oversized pistons. I like your description above. I knew you had to grind the aluminium away to leave the layer of silicone but never understood how that worked. 'acid' that's interesting. 944 man, thanks for the tip on the disks.

 

[os951]

Son have bought several parts for his engine. We considered first Tial dump, but choose this finnish made dump instead because we got it for "student-friendly-price". We also can be sure it will perform very well. This design has been around over ten years and is widely used here in Finland with many kind of turbo applications. It can handle at least 1000hp. Manufacturer is a friend's friend, so support is also near if needed [] [Image]http://i5.photobucket.com/albums/y170/olli951/9P/0542731b.jpg[/img]

Here's friend's two 951 engines with similar dump valve: 3.0L street machine

2.5L track toy

 

[os951]

My son just bought these Techart wheels from our friend Pete [] Fronts

Rears

Test fitting