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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Mon Jun 20, 2016 9:55 am 
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shep73 wrote:
that is awesome!

where did you find it?


Sorry, missed this comment earlier. Found it on GumTree in Bristol.

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Wed Jun 22, 2016 6:52 pm 
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Not too much to show in the way of pics but have been beavering away, mainly relocating stuff under the bonnet to get the fuel line routing a bit safer and install an oil catch can.

Parts are arriving on a daily basis so will be into tackling the wiring loom next week and getting all the gauges working. Then i can set about installing the knew Corbeau Clubman seats and 4 point harnesses.

Still hoping to drive this bonkers car again this summer.

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Mon Jun 27, 2016 2:02 pm 
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Been beavering away. I decided to relocate the battery, it was in the right rear boot well (drivers side) and the cable routing was somewhat suspect, it was haning loose within an inche of the clutch pedal, tucked in by the drivers seat then routed under the fuel filler cover right by the fuel lines and the cutoff switch was behind drivers seat. Ideally I would have liked it in the boot well on the left (where it is on the 944) but this would require welding a bracket in and I dont have the tools or skill for that. On top of which the cables weren't long enough. So its on the left side of the boot floor.
Attachment:
Battery box relocated and reinforced.JPG
Battery box relocated and reinforced.JPG [ 141.42 KiB | Viewed 8968 times ]


I made some brackets from angled aluminium and riveted them to the floor and the battery box. The metal plate in the battery box is bolted to the floor utilising an existing mounting point. I then fabricated some brackets and a bolt down strap to hold the battery securely in the box.

Other news.......these turned up :D
Attachment:
new seats and harnesses.JPG
new seats and harnesses.JPG [ 143.87 KiB | Viewed 8968 times ]


Very exciting but will be a while before I can fit them, unfortunately I cant get the runners to line up with the factory mounting points so another solution will need to be found (suggestions welcome).

I have also been doing a bunch of stuff in the engine bay. I haven't post pics as its not a Porsche engine but am happy to if the forum admin are happy for me too, and you guys are interested to see them.

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Mon Jun 27, 2016 5:21 pm 
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That battery would be much better positioned in the left rear footwell area. A wet battery should also really be mounted in a battery box for your safety. Consider ditching the full size one and getting a competition battery to save loads of weight.

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Mon Jun 27, 2016 6:56 pm 
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white944 wrote:
That battery would be much better positioned in the left rear footwell area. A wet battery should also really be mounted in a battery box for your safety. Consider ditching the full size one and getting a competition battery to save loads of weight.

The battery is in a box, it just doesn't have a lid, it is very secure and is a sealed battery. I cant put it in the passenger rear foot well as there will be a passenger seat so not enough space. I did consider the left rear seat recess and ultimately I think this is where it will end up but that will be part of the over winter project.

All input on the safety (and any other) aspects are welcome as this is the first time I have built a car like this e.g. for track use. Although I must stress its not a race car just a trackday toy that gives a nod to race cars.

Moving on....a bit more progress. The heater box is now cleaned up and refurb'd with new foams and a new heater core and back in the car. I have also mocked up the new switch panel in the center console using CAD (Cardboard Aided Design), the main issue was to make sure i could get the cables to the battery cutoff switch. The switches from left to right are Battery Cutoff, Fuel Pump, Ignition, Start (just had to add a push btn start), and Rad Fans. The eagle eyed of you will also spot that the bonnet release lever is on the side of the console, I am re purposing it as a choke lever to replace the one that looked like it came from a 70's Triumph.
Attachment:
Switch panel and heater box.JPG
Switch panel and heater box.JPG [ 158.72 KiB | Viewed 8954 times ]

Attachment:
Switch panel 2.JPG
Switch panel 2.JPG [ 146.55 KiB | Viewed 8954 times ]

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Mon Jul 04, 2016 6:37 pm 
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That's the rewiring done for now and the dash and center console back in, everything that I can test seems to work ok except the heater fan. The heater fan comes on and stays on as soon as the key is turned to accessory, I cant turn it off which makes me think I have connected something the wrong way and am by-passing the fan switch, any suggestions?


Attachments:
Dash rewired.JPG
Dash rewired.JPG [ 141.28 KiB | Viewed 8926 times ]

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Mon Jul 04, 2016 8:38 pm 
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I wouldn't trust rivets holding that battery box. In a front end shunt it could rip out of the sheet metal and become a missile heading your way. Best place for it is in the rear wheel well, lower down and with welded fixings to the chassis to keep it secured.

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Mon Jul 04, 2016 8:43 pm 
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It's hard to see in the pics, but does the cage have welded in mounting plates. Looks like it's bolted through the sheet metal without any additional reinforcing.

You'll also need to weld in some shoulder harness mounts. Don't be tempted to use the rear seat belt lap points. They are too low.

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1980 924 Turbo Series 1 - Alpine White & Guards Red
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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Mon Jul 04, 2016 10:32 pm 
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Carrera RSR wrote:
I wouldn't trust rivets holding that battery box. In a front end shunt it could rip out of the sheet metal and become a missile heading your way. Best place for it is in the rear wheel well, lower down and with welded fixings to the chassis to keep it secured.

I will revisit the battery location as I'm not overly happy with it, but for the peace of mind for all the steel base plate inside the battery box is bolted to the floor. The front and rear brackets I added as a belt and braces measure.

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Mon Jul 04, 2016 10:45 pm 
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Carrera RSR wrote:
It's hard to see in the pics, but does the cage have welded in mounting plates. Looks like it's bolted through the sheet metal without any additional reinforcing.

You'll also need to weld in some shoulder harness mounts. Don't be tempted to use the rear seat belt lap points. They are too low.

Appreciating the advice guys and gals, keep it coming.

The cage is bolt in and has sandwich plates under the floor (under the car). I am going to have reinforcing plates welded in in due course, and at the same time I will get something welded in for the battery.

The harnesses I have bought are street legal trackday 4 point harnesses not full on motorsport harnesses and are designed to use the rear mounting points up to a max angle of 40deg. I've double check with the manufacturer. That said, when I get the welding done for the cage mounts I will have a harness bar welded into the roll over hoop.

Right now my focus is on making the car ready to pass an MOT at the end of the month.

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Mon Jul 04, 2016 11:21 pm 
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That's 40 deg from horizontal. The rear lap mountings are more like 60deg. But good news on the harness bar install. Check out the Schroth website for diagrams on harness mounting angles. I seem to remember it was circa 0-20deg recommended

PS. Not critism. It's all the learning I went through when I did mine 5-6 years ago. No point having safety equipment if it's not safe for you in a big off.

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1980 924 Turbo Series 1 - Alpine White & Guards Red
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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Tue Jul 05, 2016 12:30 pm 
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From your reply I understand that the cage hasn't had reinforcing plates welded to the floor? When you fabricate the 'front hoop' pieces, they want to travel up the inner sill side because floor mounted feet are terrible.

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Wed Jul 06, 2016 7:36 am 
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Carrera RSR wrote:
That's 40 deg from horizontal. The rear lap mountings are more like 60deg. But good news on the harness bar install. Check out the Schroth website for diagrams on harness mounting angles. I seem to remember it was circa 0-20deg recommended

PS. Not critism. It's all the learning I went through when I did mine 5-6 years ago. No point having safety equipment if it's not safe for you in a big off.

No criticism taken, apologies if it came across that way. I'm on a steep learning curve with this so am happy to learn from your experiences.

Well, I did a test fit of the seats and harnesses and even with my forward (short legs) and tilted back driving position the harness angle is more like 50 deg :cry: . So my question now is, would I be better off in the short term reinstalling standard seat belts or using the harnesses at a greater than recommended angle? this is just for road driving and MOT, not track use. Think I know the answer :lol:

Other updates:
1. Now have seats ready to install after much faffing and head scratching I ended up using the runners off my old 944 seats. Required a little modifying (grinder, drill, jigsaw) but they work. Things like this would be a lot easier to resolve if I could weld :lol: Pics to follow.
2. Got the heater fan sorted, I had put the wire back the wrong way round and bypassed the fan switch (must take more photos)
3. The funky start button works and the washer jets once again operate from the stalk.
4. Fitted an oil breather system with catch can and re positioned the fuel filter and fuel feed line.

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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Wed Jul 06, 2016 4:00 pm 
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Assume you know why the shoulder harnesses should be between 0 and 20deg? At 50deg or more in a big frontal the force of you going forwards causes the shoulder harnesses to pull down on your shoulders. Resulting in severe shoulder pain at best. But as a worse case scenario if your race seat back snaps under these downward loads then so will your spine. If your car is in a multiple spin with no seat back then you exit the seat and have no protection as you pinball around the interior. Harness bar or bespoke welded in mountings are preferred.

Image

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1980 924 Turbo Series 1 - Alpine White & Guards Red
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 Post subject: Re: New project: 924 GT "8 Ball" track-day car
PostPosted: Thu Jul 14, 2016 7:35 pm 
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Done quite a lot of work tidying up the engine bay:-
1. relocated fuel pressure regulator/ Filter which shortens the line coming into the engine bay and much better routing to the carb
2. Rewired the Oil Pressure safety Switch (cuts fuel pump off if significant oil pressure loss) and tidied up some of the other wiring
3. New performance air filter
4. Designed and installed crankcase breather system with oil catch can
5. Reset the carb idle and mixture, much happier on tick-over now.
6. Flushed and replaced oil
7. Flushed and replaced coolant with Evans Powercool 180
8. New Rad bottom hose, and new hoses to heater core (replaced heater core)
8. HT lead spacers added
9. Replaced break booster vacuum hose and connected it to the correct vacuum post on carb.
10. Re-routed the choke cable and gave it a new bracket, operates much better now
11. Gave the engine and bay a bit of a clean

Engine is running very sweetly now, took it for a test drive and took it up to 5000rpm for the first time! Wow, what a raw and howling synphany of noise this thing makes :D


Attachments:
Engine bay 1.JPG
Engine bay 1.JPG [ 170.08 KiB | Viewed 8826 times ]
Engine bay 2.JPG
Engine bay 2.JPG [ 177.43 KiB | Viewed 8826 times ]
Engine bay 3.JPG
Engine bay 3.JPG [ 177.89 KiB | Viewed 8826 times ]

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