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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Thu Nov 02, 2017 6:28 pm 
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Some milestone progress has been made in the last couple of weeks. Finally got a clutch setup that will work thanks to the guys at Clutchfix in Yorkshire. Once that was delivered I could get the 944 drive-train installed which I am happy to say has been done. I also had the flywheel machined, lightened and balanced.


Attachments:
Lightened Flywheel.JPG
Lightened Flywheel.JPG [ 128.16 KiB | Viewed 7126 times ]
Clutch install 1.JPG
Clutch install 1.JPG [ 141.43 KiB | Viewed 7128 times ]
Clutch install 2.JPG
Clutch install 2.JPG [ 142.3 KiB | Viewed 7128 times ]
Bellhousing installed.JPG
Bellhousing installed.JPG [ 117.76 KiB | Viewed 7128 times ]
Torque tube and transaxle installed.JPG
Torque tube and transaxle installed.JPG [ 134.18 KiB | Viewed 7128 times ]

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Sat Nov 04, 2017 12:14 am 
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Great work ! its coming along nicely

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Sat Nov 04, 2017 12:46 am 
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shep73 wrote:
Great work ! its coming along nicely

Thanks. How is yours coming along?

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Sat Nov 04, 2017 10:55 am 
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very slowly ! hasn't been helped by being back at Uni, starting a new job shortly and combining all that with work and family commitments

for an MOT I need to finish the brake lines, build up the power steering, finish off some bodywork on the rear panel and passenger sill
and then think about belts, water pump, front seals maybe head gasket and so on. Going to be pretty busy with studies over the next few months so may end up shelving any more work until the spring time, although its quite nice to spend some time doing little jobs when I have a spare hour or two.

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Sun Apr 08, 2018 9:16 pm 
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Been back beavering away on this project the last couple of months now, so thought it time I did an update. I'll let the pictures do most of the talking. I've been working away on pretty much every part of the car and still quite a bit left that I want to do but hoping to get it on track on 2nd May for a shake-down, my main target though is to have it ready for Porsche in The Glen on 20th May.

The main things I have been working on are:-
- Rear suspension refurb and rebuild. Powerflex Black Series bushes for torsion bar tube and trailing arms, solid alloy torsion bar tube mounts, new spring plates with 25% stiffer bushes, and replaced the 23mm torsion bars with 24mm, added a 16mm ARB (previously had none), and using Koni Sport adjustable dampers.
- Front suspension refurb and partial rebuild. Powerflex Black series poly bushes for the control arms and standard poly bushes on the ARB. Spax coilovers.
- Refurb and rebuild brakes, still in progress
- Relocated the battery box again
- Made a lightweight clutch foot rest

Plus a whole bunch of other little things that I'll not bore you with.


Attachments:
Rear suspension refurbed.JPG
Rear suspension refurbed.JPG [ 159.23 KiB | Viewed 6818 times ]
Rear suspension mounts.JPG
Rear suspension mounts.JPG [ 169.88 KiB | Viewed 6818 times ]
Rear ARB and trailing arm.JPG
Rear ARB and trailing arm.JPG [ 166.04 KiB | Viewed 6818 times ]
Front suspension refurbed.JPG
Front suspension refurbed.JPG [ 167.3 KiB | Viewed 6818 times ]

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Sun Apr 08, 2018 9:19 pm 
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and a few more pics....


Attachments:
Dash panel and brake bias.JPG
Dash panel and brake bias.JPG [ 127.25 KiB | Viewed 6818 times ]
Lightweight foot rest.JPG
Lightweight foot rest.JPG [ 109.78 KiB | Viewed 6818 times ]
Battery Box 3.JPG
Battery Box 3.JPG [ 141.97 KiB | Viewed 6818 times ]
Battery Box 2.JPG
Battery Box 2.JPG [ 120.96 KiB | Viewed 6818 times ]
Battery Box 3.JPG
Battery Box 3.JPG [ 141.97 KiB | Viewed 6818 times ]

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Mon Apr 09, 2018 12:50 pm 
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Nice work. Should be a fun drive when it's done! :D

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Sun Apr 15, 2018 8:17 pm 
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scam75 wrote:
Nice work. Should be a fun drive when it's done! :D

I do hope so - I doubt it will ever be 'done' but I am still hoping to get it back on the road in the next couple of weeks and have it tidied up and presentable for Porsche in the Glen.

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Sun Apr 15, 2018 8:34 pm 
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I've been preparing the car for proper installation of the Safety Devices 6 point roll cage. I decided to use advanced CAD 3D modeling to produce the support plates for the main hoop as they were a slightly tricky shape, by CAD i mean Cardboard Aided Design :lol: My hitech approach worked, very happy with the how the support plates came out. Got the whole cage back in and mocked up again so that I can get the correct positioning to drill the bolt holes.

It was also very satisfying to find solid shiny metal on this 37yr old chassis, not showing any signs of its age.


Attachments:
Front leg prep.JPG
Front leg prep.JPG [ 128.38 KiB | Viewed 6729 times ]
Main hoop prep.JPG
Main hoop prep.JPG [ 134.24 KiB | Viewed 6729 times ]
Main hoop mock up.JPG
Main hoop mock up.JPG [ 104.41 KiB | Viewed 6729 times ]
Pax front support mock up.JPG
Pax front support mock up.JPG [ 126.96 KiB | Viewed 6729 times ]

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Mon Apr 23, 2018 7:51 pm 
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Been keeping on this. Got the cage support plates welded in now and sorted out my drivers seat mounting points.


Attachments:
Seat Mounts 1.JPG
Seat Mounts 1.JPG [ 130.05 KiB | Viewed 6681 times ]
seat mounts 2.JPG
seat mounts 2.JPG [ 124.88 KiB | Viewed 6681 times ]
seat mounts 3.JPG
seat mounts 3.JPG [ 138.08 KiB | Viewed 6681 times ]
Cage support plates welded.JPG
Cage support plates welded.JPG [ 104.26 KiB | Viewed 6681 times ]
Cage support plates welded 1.JPG
Cage support plates welded 1.JPG [ 128 KiB | Viewed 6681 times ]

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Mon Apr 23, 2018 7:54 pm 
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couldn't resist a mock up of the seat, harness and quick release steering wheel :D


Attachments:
seat mounts 4.JPG
seat mounts 4.JPG [ 122.63 KiB | Viewed 6681 times ]
seat mounts 5.JPG
seat mounts 5.JPG [ 118.58 KiB | Viewed 6681 times ]
seat mounts 6.JPG
seat mounts 6.JPG [ 135.97 KiB | Viewed 6681 times ]
Seat test fit 1.JPG
Seat test fit 1.JPG [ 138.11 KiB | Viewed 6681 times ]
Seat test fit 2.JPG
Seat test fit 2.JPG [ 139.68 KiB | Viewed 6681 times ]

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Sun May 20, 2018 7:44 pm 
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I've done a tonne of work on the car since my last post so #i'm going to break it down into a few seperate posts, I'll let the pics do most of the talking.

Having done all the welding for the cage and the seat mounts the interior of the car was a bit of a mess so I decided to bite the bullet and freshen it up.


Attachments:
interior preparation.JPG
interior preparation.JPG [ 147.49 KiB | Viewed 6452 times ]
Interior prepped and primed.JPG
Interior prepped and primed.JPG [ 135 KiB | Viewed 6452 times ]
Interior painted 1.JPG
Interior painted 1.JPG [ 136.7 KiB | Viewed 6452 times ]
interior painted 2.JPG
interior painted 2.JPG [ 102.03 KiB | Viewed 6452 times ]
Interior reinstall 1.JPG
Interior reinstall 1.JPG [ 124.47 KiB | Viewed 6452 times ]

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Sun May 20, 2018 7:46 pm 
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and then naturally I had to put it all back in again....


Attachments:
Interior reinstall 2.JPG
Interior reinstall 2.JPG [ 138 KiB | Viewed 6452 times ]
Interior reinstall 3.JPG
Interior reinstall 3.JPG [ 135.85 KiB | Viewed 6452 times ]
Interior reinstall 4.JPG
Interior reinstall 4.JPG [ 133.19 KiB | Viewed 6452 times ]
Interior reinstall 5.JPG
Interior reinstall 5.JPG [ 114.37 KiB | Viewed 6452 times ]
Interior reinstall 6.JPG
Interior reinstall 6.JPG [ 112.48 KiB | Viewed 6452 times ]

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Sun May 20, 2018 8:04 pm 
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One thing that has been a bit of a struggle with the RV8 3.5ltr engine in the 924 engine bay is keeping it cool. So, in addition to the radiator shrouding that I added earlier I decided to add a Thermostatically controlled oil cooler as well. For this I used a Mocal Sandwich plate and a Setrab Proline slim oil cooler. The reason for going for this particular oil cooler was two fold i) it fit perfectly into the space I wanted to use ii) it had side mounted ports which made routing the hoses simpler. However, I still had to do quite a bit of cutting and trimming to get the cooler and hoses to fit neatly. The major thing was cutting out the lower part of the bonnet latch mechanism (it wasn't being used as I have bonnet pins) , this also meant I could utilise the great cold air flow provided by the 924 Turbo 4 vent badge panel that is on the car.


Attachments:
Oil cooler mock up.JPG
Oil cooler mock up.JPG [ 147.73 KiB | Viewed 6452 times ]
oil cooler installed 1.JPG
oil cooler installed 1.JPG [ 133.83 KiB | Viewed 6452 times ]
Oil cooler installed 2.JPG
Oil cooler installed 2.JPG [ 158.68 KiB | Viewed 6452 times ]
Oil cooler installed 3.JPG
Oil cooler installed 3.JPG [ 116.25 KiB | Viewed 6452 times ]
Oil cooler installed 4.JPG
Oil cooler installed 4.JPG [ 112.14 KiB | Viewed 6452 times ]

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Sun May 20, 2018 8:21 pm 
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Finally got to reassemble the rear end of the car


Attachments:
Rear suspension installed 1.JPG
Rear suspension installed 1.JPG [ 126.18 KiB | Viewed 6452 times ]
Rear suspension installed 2.JPG
Rear suspension installed 2.JPG [ 117.85 KiB | Viewed 6452 times ]
Rear brakes refurbed and installed.JPG
Rear brakes refurbed and installed.JPG [ 144.93 KiB | Viewed 6452 times ]
Rear brake lines and exhaust.JPG
Rear brake lines and exhaust.JPG [ 123.12 KiB | Viewed 6452 times ]

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