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924S project
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Grenadiers  



Joined: 20 Feb 2007
Posts: 3221
Location: Nelson, WI & Prescott, AZ

PostPosted: Wed Jul 23, 2014 8:16 am    Post subject: 924S project Reply with quote

Been working on gathering new and used parts for my next project. This time around, it's a 1988 924S; for track, and possibly street use. I'm finally going to sell the '85 911, wife doesn't like driving it, (she loves driving the SE) and have either this or my CGT car for track days in Arizona and California. I still pine for a dual-purpose car, since our parking space down there is limited.

'Clean' table for parts! Soaking lifters in oil, cam is coated with assembly lube.
Oil pan is going out for cleaning and a Lindsey Racing oil baffle weld job.



Rebuilt 944 turbo head; new springs, guides, seals, 200 bucks!! And some used stainless steel brake lines, 50 bucks.


More new/used parts going in; Weltmeister 28mm front sway bar, Weltmeister front control arm bushings, strut brace, SPA quick release steering hub.


Powder-coated M030 924S SE struts, new Koni strut inserts, 400# springs, 30mm torsion bars.


Rearend stuff, Weltmeister bushings, 19mm rear Sway bar.


Trying to decide between using my beat-up 924S body or going to a 944 shell. Have both torsion carriers to work with.


Engine is stripped, needs a bit of cleaning! Operating table is to the left.


Trying to decide on the body is due to dents in the 924S, think it was hit, a bit.



Door gaps are perfect, no binding. Collapsed bumper shock right rear and right front. No noticeable damage to passenger side frame rail.
_________________
'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke
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KDJones2000  



Joined: 14 Sep 2010
Posts: 317
Location: Phoenix, AZ

PostPosted: Wed Jul 23, 2014 2:46 pm    Post subject: Reply with quote

Are you going to get that thing done before heading down here?

That sounds like a big project to finish before October!

Good luck with it, looks like fun. Let me know if you have any questions...

You're going to have to do some pre-load measurements on the rear link before putting those torsion bars in, and use a spreadsheet to help you get it right the first time.

Cheers, Keith
_________________
1987 924S SPEC car
Team Toofah Racing
1988 944 Turbo S
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Grenadiers  



Joined: 20 Feb 2007
Posts: 3221
Location: Nelson, WI & Prescott, AZ

PostPosted: Wed Jul 23, 2014 10:10 pm    Post subject: Reply with quote

Hey Keith, that is the plan! I'm leaving the car interior as-is, no cage, no scraping the tar off, same everything. So, the engine and drivetrain I'm working on, and with a lift, goes fairly quickly. Also, have to rebuild a Series 2 engine for the CGT car before then~!
_________________
'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke
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Grenadiers  



Joined: 20 Feb 2007
Posts: 3221
Location: Nelson, WI & Prescott, AZ

PostPosted: Thu Aug 07, 2014 12:43 am    Post subject: Reply with quote

More pictures!

The key to a clean engine for a DIY project, and no time to drive an hour to have someone else do it:


The clean engine, not quite done with the lower engine:


Clean oil pan:


Clean parts:


New parts:


Still need more parts. Of course.
_________________
'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke
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Grenadiers  



Joined: 20 Feb 2007
Posts: 3221
Location: Nelson, WI & Prescott, AZ

PostPosted: Tue Aug 19, 2014 10:07 am    Post subject: Reply with quote

My god these engines are purdy, once they're clean, and have new parts attached!




_________________
'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke
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Grenadiers  



Joined: 20 Feb 2007
Posts: 3221
Location: Nelson, WI & Prescott, AZ

PostPosted: Wed Aug 20, 2014 4:42 am    Post subject: Reply with quote

Almost done!




_________________
'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke
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TJC  



Joined: 04 Apr 2010
Posts: 707
Location: Central-ish Arizona, USA

PostPosted: Thu Aug 21, 2014 1:16 am    Post subject: Reply with quote

Nice work, looks like you're having a fun time.
_________________
'95 BMW 318i/5 "Pearl"
'80 Porsche 924 Turbo...Save or Part?
'81 Porsche 924 Turbo...Save or Part?
'86 Porsche 944 Turbo...Parting, Not Much Left!
'87 Porsche 944 NA "Liebchen"

Still on the Prowl!

www.ttrs1.com
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Grenadiers  



Joined: 20 Feb 2007
Posts: 3221
Location: Nelson, WI & Prescott, AZ

PostPosted: Thu Aug 21, 2014 2:15 am    Post subject: Reply with quote

Well, at first it wasn't fun, P/O didn't take care of the car/engine. Lots of oil, dirt, grease, ugh. However, once cleaned, and the parts came in, yeah, has been a lot of fun. Last night, took the torsion carrier apart, burned off the old bushings, and today, installed delrin, and it's back together. About 3/8" apart on height difference between the two sides. However, I'll wait till I get the 15x7 wheels with tires on and choose which height to keep. And, having the tools to do this is what makes it doable for old guys~!
_________________
'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke
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Grenadiers  



Joined: 20 Feb 2007
Posts: 3221
Location: Nelson, WI & Prescott, AZ

PostPosted: Thu Aug 21, 2014 4:08 am    Post subject: Reply with quote

Here's the axle all assembled, looking at it, hmmm, 'how am I getting that up into the car?'.

Well, a scary bit of ingenuity, but it worked! Kind a hard to see with all the junk in the background. But that's cheap cable hoist connected to the rear control arm bracket!

Only had to lift it as high as the tranny jack, but that's too high for this old fart.

Ooops, forgot something.

It's in!

Lightly used stainless steel brake lines.

_________________
'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke
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Grenadiers  



Joined: 20 Feb 2007
Posts: 3221
Location: Nelson, WI & Prescott, AZ

PostPosted: Mon Aug 25, 2014 11:01 am    Post subject: Reply with quote

Did the manual sunroof conversion, using my Cali car's 'orange' sunroof. Nice tight fit, using the 924S seal. Think I'm going to go from calling this the ugliest track car, to 'carrot top'. Also, attached the clutch and bellhousing, and those sensor things. Still waiting for answers on replacing the engine fuel lines before install.
_________________
'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke
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Grenadiers  



Joined: 20 Feb 2007
Posts: 3221
Location: Nelson, WI & Prescott, AZ

PostPosted: Tue Aug 26, 2014 9:03 am    Post subject: Reply with quote

Ugh, hate this part. Prior to this, I cut the OEM engine fuel lines below the brake booster. Waiting for fuel lines from Paul.



THAT took too long, but with just me and a crappy engine hoist, took longer than it should. Even hooking up the crossmember made me cross! Sweated out 6 beer as well. Arghghhghg. More tomorrow.
_________________
'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke
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Zeek  



Joined: 09 Jul 2010
Posts: 107
Location: Shady Side, MD

PostPosted: Tue Aug 26, 2014 2:09 pm    Post subject: Reply with quote

Looks great! Remember: lift with your back.
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KDJones2000  



Joined: 14 Sep 2010
Posts: 317
Location: Phoenix, AZ

PostPosted: Wed Aug 27, 2014 3:14 am    Post subject: Reply with quote

Are you keeping the A/C in there? If you aren't then you don't have an adjustment for tensioning the Alt drive belt. You'll have to get an A/C delete bracket and fab up a tensioner for the Alternator, after you relocate it to the A/C location.

Things are going to be tight in terms of schedule, methinks....
_________________
1987 924S SPEC car
Team Toofah Racing
1988 944 Turbo S
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Grenadiers  



Joined: 20 Feb 2007
Posts: 3221
Location: Nelson, WI & Prescott, AZ

PostPosted: Wed Aug 27, 2014 4:47 am    Post subject: Reply with quote

Hey Keith, I'm going to pop in the a/c unit for now, running out of time. Have till the end of September to get things done, and should be able to on this project. The rebuild of the 2.0L will have to wait till I get to Arizona, have engine hoist and engine stand there as well. I'm sick of this project of course, I'm now 'rassling with the motor mounts, and I'm losing 2-1, taking a much needed beer break! We might have a buyer for the restaurant and hobby farm, so may not be able to make it there in early October. So, still want to do the las vegas chumpcar, but will have to let you know in a couple weeks. dave
_________________
'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke
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View user's profile Send private message
Grenadiers  



Joined: 20 Feb 2007
Posts: 3221
Location: Nelson, WI & Prescott, AZ

PostPosted: Wed Aug 27, 2014 6:43 am    Post subject: Reply with quote

Well, after 4.5 hours, the engine is in. I had installed the driver side first, big mistake. Do the passenger side first, and you're good to go. After removing driver-side mounting arm, took only a half hour to get it all attached. Grrrrrr. Oh well, 2.5L virgin, so, the learning curve can be pretty steep at times.
_________________
'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke
Back to top
View user's profile Send private message
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