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So with the cage in place I really fancied connecting it to the A and B posts to stiffen the shell up. A couple of hours playing with some old wheel bolts and big washers produced this home made swaging tool.....[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMAG0655_1.jpg.html][/url][/url]
Which after a bit of practice allowed me to come up with these......[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMAG0657_1.jpg.html][/url][/url]
[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMAG0660.jpg.html][/url][/url]

Finally I've got the cage welded and a quick splash of primer on to stop it gathering surface rust. Although as soon as the paint had dried I started to remember other bits that needed fabricating and welding to the cage! Thankfully not too much as I've had enough of grinding and welding for a while, but I still need to make a switch mount and a battery cradle before I can put anymore paint inside the car.[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMAG0661.jpg.html][/url][/url]
[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMAG0663_1.jpg.html][/url][/url]

Some nice fab work gone in there.

I recognise your car, name and fab skills for that matter

You're the Bruce that had the 2 x CIS fuel dizz engine right?

Following this with great interest. If the last engine is anything to go by, this should be epic/insane.

Nice choice of turbo

Wes, top marks for observational skills and memory! Yes the car was the one with the 2 cis fuel distributors, it was parked up probably 8 years ago in a damp lock up (which then had the roof ripped off in a storm), whilst I got on with a long winded divorce. Once the solicitors had stopped sending me huge bills, I dragged the car out, very wet, damaged and at this point not running and attempted to resurrect it. After a lot of messing about it became apparent that if I was going to do it, I should do it properly, so I decided to start with an engine swap since 2.0 litre parts were becoming harder to find and I'd reached the limits of the cis system. I've still got the 2.0 litre bottom end propping the work bench up and loads of cis bits kicking about if you need them, I've also got a pair of 30mm rear torsion bars which I should sell.

More grinding, more welding, but more progress.....With the cage pretty much sorted it was time to move back to the engine bay and start finding somewhere for the radiator and the fuel tank. Thankfully I can live with a 10 litre tank and a small radiator..........[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMAG0694_1.jpg.html][/url][/url]
With the mounting brackets in and the mandatory frame to protect the fuel tank in place, a quick coat of paint and then drop an engine back in place to try and start working out fuel, water, oil and intercooler pipes.[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMAG0695_1.jpg.html][/url][/url]
The fuel and oil pressure pipes will be made up from billet fittings and high pressure PTFE lines, which would be a really easy and cost effective way of replacing the standard fuel pipes on a 924/943/968, as you wouldn't need to drop the suspension down. As a teaser these are the fuel filter and fuel rail fittings.......[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMAG0871.jpg.html][/url][/url] the filter can be fitted either before or after the pump depending on the fittings.

With the weather improving and my shifts switching to late starts, I've managed a few weeks of decent work on the car. The engine is bolted in properly and the clutch all seems to work, although to get the correct feel I've had to fit an OBP hydraulic clutch pedal as I couldn't get the position of the master cylinder right with the standard pedal (my pedals have been moved across 30mm to allow for the clutch to swapped from inside the car). [url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMAG0866.jpg.html][/url][/url]
[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMAG0867.jpg.html][/url][/url]
Ive also bought a cheap Chinese bead roller and made some floor panels, I've even sat a seat in place so that I can sit and make engine noises! [url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMAG0741.jpg.html][/url][/url]
[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMAG0743.jpg.html][/url][/url]

I managed to get a few long days working on the car by using a bit a leave up that I was owed, so with the kids off playing with the horses, it was time to make a wiring loom. Theain board is bolted to the floor with rubber mounts (to help with vibration since the engine is on solid mounts), the Anderson plug is for connecting a booster battery since the car battery is only a small AGM unit mounted under the boot floor.[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMAG0913.jpg.html][/url][/url]
The ECU will also mounted to this board.
This is showing the switch panel which has the fuses built in to it, as well as the rev counter, oil pressure light and shift light. These are hung from the windscreen support (needed because the front screen will be 4mm Lexan).
[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMAG0916.jpg.html][/url][/url].
The next job is to build an engine loom, and make all the ancillaries (water pump, vac pump, engine breathers etc) fit.

Nothing constructive to add, but your work is amazing, enjoying watching this take shape

Absolutely, following with interest

Ditto...will be stealing some ideas for my 924 V8 track day car.

I've been on late shifts for the last 2 weeks, which gives me loads of garage time (drop the kids at school, then 5 hours on the car before work, although the garden is looking a bit sorry for it's self!) So a huge push on with it and it's finally starting to come together. The wiring is all done with the ECU in place and the engine loom made, hopefully I've done it right since I've wrapped and tied it all in but not tested it! I've read and read and read everything I can find about programming an ECU and come up with what I hope is a decent fuel and ignition map to start it up on.[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMG_20170515_122601.jpg.html][/url][/url]

Next on the list was the engine breathers, I've gone from the cam cover and engine block to a catch can/oil separator, then from that to an electric vacuum pump. The pump pulls enough vacuum to make suck the oil cap on pretty well so hopefully it'll relieve the crankcase pressure.[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMG_20170523_112100.jpg.html][/url][/url]
[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMG_20170523_112050.jpg.html][/url][/url]

Finally I got the bonnet and tailgate mounted and secured. On the tailgate I decided that the factory catches were unreliable and I didn't want bungee style straps so I made brackets to hold 1/4 turn dzus fasteners, these simply bolt to the tailgate instead of the pins.[url][URL=http://s154.photobucket.com/user/bruceakop/media/Porsche/IMG_20170523_112226.jpg.html][/url][/url]

The Lexan is all cut and painted for the screen and side windows, so that should go into place today, then I may get chance to roll it out of the garage and tidy up!

It runs!! I swapped out the standard 200cc/min injectors, fitted a set of 850cc/min ones, pulled some fuel out of the map and hit the start button. It fired up first press of the switch. After a bit of playing about with the timing table it would rev cleanly up to 7k, and sounds really angry with the short stubby exhaust exiting straight out of the OSF wing. Hopefully I'll get a bit of time over the weekend to finish off the cooling system then I can see if it will move under it's own power. Since photobucket has ruined my thread, I'm going to stick all the pictures on a Facebook page, which I'll put a link up to soon.

Here are a couple of start up videos.

https://youtu.be/arK1EkCiYZw

This was the very first start, it was running very rich and there was plenty of oil in the bores from assembly.

https://youtu.be/t0jBmNR6vq4

This is after a couple of hours of tuning, it's a lot quieter as it's running through an exhaust extension to keep the fumes out of the garage and to keep the noise down a bit as my neighbours are grumpy at the best of times!

It drives! I've had a couple of shakedown runs with it, the only issue (apart from it still needs mapping on a dyno) is that the gearbox jumps out of 1st gear under load, so I need to pull the box out and swap it. The tracks aren't open until next March now so I've plenty of time to sort it out.