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Build a clutch disc for your 924S/944
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joecitizennn  



Joined: 12 Sep 2005
Posts: 2096
Location: no mans land

PostPosted: Wed Jun 17, 2009 1:38 pm    Post subject: Reply with quote

yes I kept the old pressure plate as well as throwout and pilot bearings on this particular job, they were all in good shape. But this will not always be the case. One time I found that the pressure plate had slight warp to the spring fingers and the surface of the plate face was discolored and cracked from heat. I quickly replaced it with a spare from my parts pile. Another time I had a gritty throwout and I swapped it for a smooth one from the same parts car. There is an advantage in collecting and stripping parts cars, as well as buying used parts for cheap prices as they come along. Some guys like to dump thousands upon thousands of dollars into cars not worth more than a few thousand to start with. I like to achieve good mechanical tune for much less. For me it makes the 924 hobby more enjoyable and much more interesting.
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Jrboulder  



Joined: 18 Oct 2010
Posts: 30
Location: Boulder, CO

PostPosted: Fri Nov 19, 2010 4:26 pm    Post subject: Reply with quote

Sorry to drag up an old thread but I would love to know the spacer length. It seems like it is about 1/2 inch but I would like to know what it is and what tolearance I have.

Thanks,
Jackson
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joecitizennn  



Joined: 12 Sep 2005
Posts: 2096
Location: no mans land

PostPosted: Sat Nov 20, 2010 12:36 am    Post subject: Reply with quote

do you want to know the spacer length or thickness? The length and shape is determinde by the disc you are using.
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Jrboulder  



Joined: 18 Oct 2010
Posts: 30
Location: Boulder, CO

PostPosted: Sat Nov 20, 2010 1:32 am    Post subject: Reply with quote

Oh, sorry. I want to know the thickness of the spacer. The amount I need to offset the hub to make it clear the flywheel. I am using the exact part # you stated. Thanks.
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joecitizennn  



Joined: 12 Sep 2005
Posts: 2096
Location: no mans land

PostPosted: Sat Nov 20, 2010 10:25 am    Post subject: Reply with quote

1/2"
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Jrboulder  



Joined: 18 Oct 2010
Posts: 30
Location: Boulder, CO

PostPosted: Sat Nov 20, 2010 1:02 pm    Post subject: Reply with quote

Awesome! Thanks so much for the write up and your help!
I ordered the plate today and get it tomarow.
It was $32
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joecitizennn  



Joined: 12 Sep 2005
Posts: 2096
Location: no mans land

PostPosted: Tue Mar 06, 2012 11:30 pm    Post subject: Reply with quote

Thought I would share some "test of time" pictures.

This is the custom built clutch disc after 70K miles. No worse for wear... other than the dirt its almost new! It even still has some of the original milling marks in the face of the friction material from when it was manufactured.






_________________
87 924s
88 924SE gone
447 hp cgt clone
87 924S gone
84 944 sold
83 944 sold
89 turbo S LSD, ABS etc
86 951 white rocket
85 944 sport everything.
84 944 sold.
87 944 sold
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leadfoot  



Joined: 11 Dec 2002
Posts: 2222
Location: gOLD cOAST Australia

PostPosted: Sat Mar 10, 2012 3:28 pm    Post subject: Reply with quote

if you send me the pcd and bolt hole sizes/ ID and OD measurements I'll do up a CAD/DXF file so you can get the spacer water jet cut from and engineering company,
should save alot of fiddling about and help with the overall balancing...
I'll also split it up into 4 pieces (on the same file) so you could get it made from another material if you prefer, delrin, poly urethane etc etc...
cheers
Stu
_________________
1981 ROW 924 Turbo -
carbon fiber GT mish mash
LS1 conversion in progress...
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tyfighter123  



Joined: 19 Jan 2010
Posts: 542
Location: Colorado

PostPosted: Sat Mar 10, 2012 4:11 pm    Post subject: Reply with quote

Ohhhhh that would be nice!!
_________________
Porsche 924 1977 N/A
Mustang GT/CS 2007
Porsche 924S 1987 (parts car)(cut up and recycled)
Porsche 911S 1976
Porsche 931 1980
Porsche 931 1980 (parts car)
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joecitizennn  



Joined: 12 Sep 2005
Posts: 2096
Location: no mans land

PostPosted: Wed Mar 14, 2012 4:29 am    Post subject: Reply with quote

leadfoot wrote:
if you send me the pcd and bolt hole sizes/ ID and OD measurements I'll do up a CAD/DXF file so you can get the spacer water jet cut from and engineering company,
should save alot of fiddling about and help with the overall balancing...
I'll also split it up into 4 pieces (on the same file) so you could get it made from another material if you prefer, delrin, poly urethane etc etc...
cheers
Stu


That sounds cool, but finding the time to take it apart....
_________________
87 924s
88 924SE gone
447 hp cgt clone
87 924S gone
84 944 sold
83 944 sold
89 turbo S LSD, ABS etc
86 951 white rocket
85 944 sport everything.
84 944 sold.
87 944 sold
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tyfighter123  



Joined: 19 Jan 2010
Posts: 542
Location: Colorado

PostPosted: Wed Mar 14, 2012 4:52 am    Post subject: Reply with quote

Awwww come on Joe you know you want to take it all apart! JK I don't blame you!
_________________
Porsche 924 1977 N/A
Mustang GT/CS 2007
Porsche 924S 1987 (parts car)(cut up and recycled)
Porsche 911S 1976
Porsche 931 1980
Porsche 931 1980 (parts car)
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hdrider19  



Joined: 03 May 2016
Posts: 193
Location: Catawissa Missouri(40 mi sw of St Louis)

PostPosted: Wed Jul 27, 2016 3:08 pm    Post subject: Reply with quote

Thanks for a great how to. I am doing this right now. I tried a disc from pep boys but it had wrong center. Went to autozone and got the right disc. New throw out and pilot bearings. Pressure plate looks good just rusty from non use. Sand blasted and then block sanded friction surface with Emory cloth. Thanks again. Paul
_________________
87 924S
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edredas  



Joined: 09 Dec 2004
Posts: 855
Location: Charlotte, NC

PostPosted: Tue Feb 14, 2017 8:55 pm    Post subject: Reply with quote

I made a video on making this clutch disc, for anyone interested. My discs always work great but I need to work on getting my rivets to look nicer

https://www.youtube.com/watch?v=LcdzwvdWKEM

This is the disc from the video. It is a new Auto Zone D1041 that I paid ~$50 dollars for. Advance no longer carries the $28 re-manufactured RFCF48801 disc, so I had to find something else that would work. This is very similar to the advance disc and should work great!



This is the first disc that I built using the $28 Advance disc. I used this clutch for several years and was only a little dirty when I pulled it out. I will likely use it again in another project. You will break the transaxle before you break this disc... BTDT


_________________
'86 944 -Garnet, Fully loaded, Koni suspension
'87 924S -Red, 300hp 951 swap
'87 924S -Red, New Project
'87 924S -White, Automatic
'88 924S -Red, Daily Driver, Bone stock
'93 Mx6 -White, Megan Racing suspension
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