Porsche Enthusiasts Club Forum

Pics tommorrow. Spent a bit of today removing parts from donor car!

direction of the drivetrain has changed after much deliberation. I just didn't have trust the 924t engine would be up to what I wanted, and with parts rarity and costs pretty high compared to more modern stuff I decided to go with one of my favourite engines which will cope with mega power and be reliable. lots of good parts to bolt onto this shell now and a direction to pursue now the decision has been made.

complete rear beam setup. all rebuilt/blasted/coated etc. polybronze bushes from the states by elephant racing. torsion bars removed (poly bronze bushes give solid supports and replace the support the tb's give) black series poly bushes installed in trailing arms and body mounts. solid aluminium mounts to body replace the rubber type.



gaz gold coilovers all round, with camber adjustable spherical bearing top mounts. solid mounts shown as well.


audi S6 AAN engine. 2.2 5cyl 20v turbo. engine fully rebuilt and as new, ready for big power and incredible noise!


924 turbo bellhousing fitted along with audi rs4 spacer plate to allow clutch fitment


new rebuilt driveshafts


trailing arm polybushes


body mount solid polybushes


winner racing 951 radiator


tilton twin place paddle clutch for big power! also a brand new AET turbos, kkk k24/gt2871r ball bearing turbo. this came in the package of parts I bought, but I will be selling this item and going for something like a garret gtx3076r or gt3082r for over 500bhp. (note this turbo will work on a 944turbo for anyone interested in buying)


audi tfsi coilpacks to be fitted. also 034 motorsport garret turbo oil and water line kit to allow garret turbo fitment.


next stage is to continue with the shell to put all the strength back into it so I can start dummy fitting parts.

will hold fire on shell progress pics until I get to a more complete stage as I have been doing lots of little bits all over the place.

I also have all the drivetrain parts ready to bolt on, front steering/suspension components, torque tube, gearbox etc. so I can get all the fab work done on the shell so everything bolts on. whack a new t45 multipoint weld in cage into the shell, fuel cell, and close all the rear end in. then we can get all the body panels fitted (widebody) and send shell for paint to start bolting bits on!

I just require an exhaust manifold and the correct turbo before I mount the engine so as to ensure it all fits. I will be fabricating a custom inlet manifold with front inlet, and also fitting larger front mount intercooler along with the 951 rad. then its intercooler pipework and exhaust to get all the engine plumbed in ready for custom car loom and standalone management.

reason I went for the aan engine is that I have an audi rs2 which has the ADU version of the same engine, and its just an awesome engine that makes an incredible noise, as well as being super strong and capable of big numbers with no stress. it also stops me from the huge temptation to tune the RS2 as that needs to stay stock!

anyone questioning the balance of the car etc due to the extra cylinder, the aan engine is actually shorter than the original 944 engine by approx. 50mm so it will sit no further forward than the original engine. i want to have a look and see if i can shorten the driveshaft slightly to get the engine right up against the bulkhead, but that all depends on how much spare spline length there is available. the other option is just to mount the gearbox very slightly further back to achieve the same thing, or possibly a combination of shortening the driveshaft and moving gearbox mounts slightly. there is approx. 2 inch gap between back of engine and rear of cylinder head. if i can get it back against the bulkhead, then the engine will sit flush with the front edge of the turrets! which means no overhang in front of the suspension mounts!

cant wait to get it all bolted in the shell! this car should be pretty incredible with wide body and over 500bhp, coupled with a target weight of 1000kg max.

more progress pics and updates to come soon. hope you like.

regards
nick

forgot to post these from a while ago, just a mock up of the rear arches. and rear arches cut out to allow maximum clearance. new inner to outer skin will be fabricated that meets new 1/4 panel.















tyre in the arch was an 18inch slick 25/64/18, just a mock up as I had them lying about and just gives more of an idea of the look once a wheel is in the arch.

Very exciting Nick.

I need a tissue!

Nick

With all that room at the back and all the power to be handled have you thought of a 996 rear end? There's a Swedish guy who posts a few details of his build in a blog here http://www.modsport.se/index.php?mact=News,cntnt01,detail,0&cntnt01articleid=188&cntnt01origid=56&cntnt01detailtemplate=Nyhetsvisning&cntnt01returnid=67

I've copied a few of his pics to give you the general idea:





Advantages include:

• Modern easily adjusted multi-link rear suspension with (reasonably) low unsprung weight
• Longer and lighter shafts with larger joints
• Bigger, cheaper, easier (and neater) brakes
• Anti-squat, camber gain, roll centre
• Better choice of dampers
• Wide range of light strengths (and stylish) BBS rims
• Full complete rear end about 10kg lighter than the standard

He used a 996/997 cup diff in a 968 box but was able to use standard length 996 driveshafts. He also grafted on a 996 front end too, but that's another story.

I know you are a long way down the road already, but wanted you to know about this mod if you hadn't already come across it

Cheers

Rob

Hi rob. Yes I think someone has mentioned that setup before somewhere on the forum. I can see the benefits it would give. But for the minute I would like to try and keep it 924/44 based. If I find once up and running there are any issues with the back end that might need addressing then it is something I may consider.

Well good luck and if my dream 3.0L 16V turbo ever gets built then you will be doing one of those back ends for me

Rob

Cheers looking forward to getting stuck into the project now I have a direction decided! We have a customer 944 turbo being fully rebuilt from the ground up alongside this, and we have been doing a lot of fab work for a 3 litre 16v turbo engine as well! Also have a 924 n/a and 944s2 both awaiting shell prep in the near future so lots going on! Also expanding into a new refurbished unit twice the size so we have the workshop to be able to cope woth the work!

If you decide to pursue your 3 litre 16v project then give us a shout! Check out build thread by sgl1966 on this forum (944 s2 repair) to see the work on the 16v turbo engine. It can be done for less than you may think!

Does anyone know if there are any differences between torque tubes on different models? Mainly thinking of strength? I have tubes from 924t. S2 and 944turbo available to use!

Not sure whether you have said where you intend to race this car when it's finished?

Have a look at the CSCC "Special Saloons and Modsports" series. I assume it would be eligible; it would be worth asking the question of the club office anyway. It would be great to see it performing on track alongside iconic cars such as Baby Bertha as well as some of the modified Imps, Minis, Elans and Skodas of the 70s and 80s.

Been purposely out of the loop for a while.

Interesting change of direction Nick. With your skills, maybe you could start selling engine conversion kits to go this route?

Anyway, have you decided which Holset you're going to bolt to this yet??

Driftworks dudes are right - HY35 should do 500hp (65/58mm turbine IIRC). HE351 generally has the same turbine as the HX35 (70/60mm) and a very large compressor wheel so is good for more if you get bored with 500

Not really got a race series in mind tbh! Just building it how I want it really ! Once its done if I can enter it in some races that would be great! We are a long way from that point anyway atm.

Wes I may possibly think about doing install kit, but obviously depends on potential market! For the minute I want to concentrate on getting this installed first lol!

Turbo wise been doing lots of research and the hy35 with 10cm housing by compressor racing looks a good option. But also been looking at borg warner efr series but price difference is large. You cant really go wrong with the holsets as they do the same job if not better than similar turbos 3 times the price!

The fact they are designed to run on trucks that run at 3 bar boost and last for a few hundred thousand miles, installs a lot of confidence in reliability! I have customere running garrets that constantly blow up after a years use. They switched to holset and have similar if not better spool and power, but with 3 years reliable service!

The fact you can buy a brand new turbo for 500 pounds is incredible. And nowcompanies have cottoned onto how great they are there are options for hybrids and billet conpressor wheels etc perfectly suited to petrol car use.

The hy35 should give 500hp with ease, and give full torque before 4000rpm and hold to redline which gives a perfect powerband for race/track use between 4 and 7500rpm. A turbo that spooled quicker would actually be a waste bearing in mind the car will never drop below 4krpm.

At the min im looking at the compressor racing hy35, or the hx35 super hybrid, or possibly hx35 with 12cm housing.

Tbh with 500 ish hp and around 650nm torque, combined with rwd and 1 tonne, should provide enough power to scare me silly!

very small update. offered the rear suspension setup into the shell as this ties all the rear end together so I can start to install the cage to put strength back into the shell.

fits nicely!





for reference this is late 944 spec rear end made for abs, so the track is a fair bit wider than 924t stuff. approx 30mm a side wider. this helps slightly when filling the silly wide arches! I offered up a d90 8j for reference, and worked out the rear will require something like a 12j et10 to fill the arches properly.

had a quick play with the front end this eve. just offered up the combination of front end components I intend to use.

consists of 924t front subframe, 924 manual rack and uj. 951 aluminium wide track bottom arms, 951 hubs, and gaz gold coilovers with adjustable top mounts.

this combination allows bolt on subframe/rack and uj can all be utilised from original car. the 951 wishbones give wider track, and allow use of 951 hubs which will allow bolt on fitment of big brembo calipers or similar.

only modification I had to make was to cut out a bit of bracing inside the subframe which the 951 arms hit on, which means the bolt wouldn't go through the subframe/wishbone bush. new bracing will be added and subframe strengthened as well. very easy modification.

just waiting on rack to turn up, and I will extend tie rods to suit extended track wishbones. I have 26.8mm front arb to fit as well.
(arb sizes will be played with to achieve desired balance, just going to start with 26.8 front, and 16mm rear, then adjust to suit balance)
most people would say I want m030 968 items which are 30mm front and 18 or 19mm rear. but you have to remember this car is very light, and also with stiff suspension springs the arb job is reduced anyway, so a very stiff arb setup may actually just reduce grip and cause over/understeer. we will start with this setup and then change arb's to achieve the kind of handling required. big stiff ARB work well on road cars, where softer springs cannot reduce body roll as much in the corners, and so the stiffer arbs used take over as a spring to reduce roll on cornering but still maintaining a nicer ride due to softer springs. arb choice on race cars is a different science, and mainly trial and error with testing is the best way to find a good balance. it will be apparent very quickly if the arbs are to small.