Porsche Enthusiasts Club Forum

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I already have an S2 crank and pulley Simon. I have everything to build a 3.0 8v engine now, except motivation.

£600 fro the crank if anyone interested .

Well it took a little bit more than clearancing ! To make room for the inlet and outlet banjo's had to do some cutting and welding of subframe and add a couple of brackets , but has come together well for a cheap 2.2 turns quick rack . Will use the astra electric pump I have on the other car mainly just for the childish noise it makes powering up but it also is working well and you can locate it where you want . The rack is very similar in size to the 944 rack as can be seen in last photo .
Also have these old Bilstein coilovers which came from a 993 but have a 964 part number 9643351070 which I can find nothing about on google . I have a sneaky suspicion they are a rs or motorsport part as the coilover thread goes all the way down unlike a normal 993 strut .
You can see in picture late 944 spindle on strut .
The great thing is the flange width fits a late 944 spindle (18mm) and the lower bolt hole lines up . I am just going to cut an elongated hole for the top camber bolt lower down . They also take a 2.5" spring and use an insert which can be replaced or rebuilt . If anyone knows what they are from please let me know .
Trying to build a cheap hillclimb project using up the mountain of parts I seem to have hoarded to make some room and not buy lots of go faster goodies . Just waiting for paint shop to fit me in for a weekend cash job before I can start bolting some of these parts on .

Very interesting stuff as ever, good to see it all coming together!

No idea on the strut I'm afraid.

Stuart

Thanks Stuart , early retirement meant it was either stamp collecting or this .

A wise choice indeed, modifying stamps is frowned upon, could have ended up in all sorts of trouble with the authorities..................

Just got my rebuilt AOR gearbox back from RSR Porsche , Dave in Droxford and Russell in Camberly . Useful for us southern softies .
Really helpfull Indy unlike some in the south and Russell has done a great job on the gearbox including rebuilding the lsd .
Russell also had some interesting stories with period pictures about working on and with a race team on one of the four race 968RS Turbos back in the day .
And a years guarantee !
Anyway its back , the shell has gone for a coat of paint inside , engine bay and underneath so I can start bolting some bits on . I have learnt that I am a clumsy sod so not worth painting outside of car until its together .
The oil cooler is my own design as it doesn't have much function on a sprint /hillclimb car so a bit of braided hose is a safer option than the brittle original that are prone to crack .

Looking good! Brings back some painful memories looking at an AOR box close up!

I contemplated just a simple loop for the cooler at one point but ended up going down the mini rad route. I actually was looking through my history file today and noticed it cost me £240 to buy all the parts for the conversion. £90 for the adapters was scandalous to be fair, and I think £84 for the mini rad, but its a good one. Must have been £60 odd quid for the hose and various angled fittings to put it all together, seems quite a lot but hey ho. I'm sure I got super strong braided re-enforced rubber hose just to be extra safe! Still way cheaper than another AOR rebuild though!

5 years down the road and it hasn't lost a drop of oil and it will never fracture, so well worth it. That aluminium cooler loop has got to be one of Porsche's worst ever designs. I got through 3 before the box finally bit the dust, and they all leaked a bit from the low connection into the box. Having a lowered car definitely doesn't help the cause!

Stuart

Hi Stuart , yes I have that loop on the other car and it does worry me , will change it out next time gearbox out .
Getting expensive to rebuild these things . I supplied bearings and seals which must add up to £1200-£1500 , that’s every bearing . Some are nla from porsche so had to get two from Kevin Goss in USA , gearbox guru , who removes and stores them if good while dismantling a box .
RSR charged me labour and shims .
Gearbox is a black art to me and very few people have the correct tools to set up even gearbox specialists ,
I have also redone my torque tube bearings so will end up with a really quiet gearbox and torque tube in a competition car with no sound deadening , madness .

Sounds good Simon!

I was quite lucky as I know an old school local gearbox guy who used to work on rally cars. His labour was pretty cheap as well.

I'm sure I ended up spending the thick end of £2.5k all in though. Had to buy a non LSD box to put in while the AOR was in theatre, then the first build produced a whiny box due to crown and pinion damage (I was warned but told him to try anyway as we couldn't locate a good crown and pinion at this point), this was done while the spare box was on my car. Eventually had to take out the non LSD box and let him make the best box he could from the 2 boxes plus the box of bits you sent me. Luckily the crown and pinion in the non LSD box was mint. You can still get them from Porsche for £1k!

As I wasn't taking the boxes in and out my car myself, I ended up paying for multiple gearbox swaps during the process. I definitely don't want to do that again!

My TT is original, but still fairly quiet and the box is now pretty decent but can have a bit of idle chatter when warm, though not always, and 3rd and 4th make a slight whine over about 3k revs. It's definitely a Frankenbox, but it's worked fine since and that's about 4 years now and 25k miles. LSD was the only thing that survived in the original box.

Stuart

Isn't there a Passat diesel gearbox that's very similar? And could probably be bought for a few hundred from a scrapyard?

Like this DQS O1e audi diesel gearbox I have in the back of the garage . O1e gearbox's are getting harder to find and more expensive as they are much stronger being used on gt40 replicas to v8 drift cars .

Do you know what years and cars it was fitted to Simon? And is it easy to identify when still in the car.

Some interesting stuff here about comparison and merits vs 016 boxes. The pictures don't seem to be there though but a lot of info.........

https://www.gt40s.com/threads/compariso ... les.15580/

Passat boxes seeming have the same bolt pattern as the 016 and the box is seemingly good to handle 100BHP more than a 016.

Stuart

Forgot attachments !
From memory around year 2000 2.5 TDI 6 speed Fwd Passat . Sqr is one of the better models with the wider first gear (stronger) . You can tell by the bulge on the gear casing compared to a 968 box , 968 box on left .
Not as plentiful or cheap as they once were .
I was going to use this but the regs we are putting the car together for say gearbox has to be porsche based and I had an AOR in bits so this is in the parts section with a splined coupler for torque tube and the shorter LH 968 cv that will be needed.