Porsche 944

[cybe]

So, here's my (re)build thread.

 

I watched this one sit in front lot at Del-Car for a few years - $2500, $2000, $1500, "Needs Clutch," $800.

 

http://i.imgur.com/kLhcsEw.jpg

 

Reach in through the missing window, push snow off the seat. Pop the door. Check out the option codes:

 

http://i.imgur.com/vkVbDpF.jpg?1

 

Nothing special - no coveted limslip diff.

 

 

 

Known issues so far:

 

No keys,

No ignition switch,

Missing rear quarter window,

Busted fender,

Door pulls inoperable,

Sunroof inoperable,

Doesn't start,

"Needs clutch."

 

Tossed a battery in it and turned it over with a screwdriver. No fire, but it rolled over and dropped the rear-view mirror on my lap - like an abused puppy.

 

Sold.

 

 

 

I'm not a mechanic. I've done parts and gaskets replacements, suspension work, various mods - but never really put an engine together. By my logic .. for $800? How could I go wrong?

 

 

 

Motor out. Manual says to drop it through the bottom - in a one-car garage? To hell with that.

 

http://i.imgur.com/kA91eMU.jpg?1

 

Split the bell for easy access / clearance.

 

http://i.imgur.com/xLR496H.jpg?1

 

http://i.imgur.com/YdHYDKt.jpg?1

 

I took a bunch of parts off and sent them off for blasting and rebuilds. Alternator, Starter, Power Steering, Oil pump, Water pump, Throttlebody.

 

Hite Parts, McKinley Ave

 

 

http://i.imgur.com/yvC5ZYY.jpg?1

Edited May 10, 2013 by cybe

[cybe]

This what I found:

 

Block

 

http://i.imgur.com/iM5Ckkl.jpg?1

 

Head

 

http://i.imgur.com/zkkQCHu.jpg?1

 

Cam tower

 

http://i.imgur.com/YrXYELe.jpg?1

 

I sent all that to M&M Cylinder Head for voodoo.

 

 

 

 

The worst part was the friggin' woodruff key in the crankshaft.

 

http://i.imgur.com/jvmmrP9.jpg?1

 

I torched it.

 

http://i.imgur.com/syqpjNe.jpg?1

 

I froze it.

 

http://i.imgur.com/ZzYwdwH.jpg?1

 

I filled the pulley and let it just burn.

 

http://i.imgur.com/CAzWLGr.jpg?1

 

 

And then I broke it. The keyway for the woodruff key, the slot at the end of the crank. I fucked it up. So I got another block.

 

http://i.imgur.com/hVETxkC.jpg?2

 

http://i.imgur.com/d99TLXg.jpg?1

 

And it had updated pistons! +30hp!

(no, really -- plus 30)

 

http://i.imgur.com/TrrJxeu.jpg?1

 

It also had .. good bearings!

 

http://i.imgur.com/iyXZptl.jpg?1

 

 

 

 

The parts came back clean

 

http://i.imgur.com/bGYpnis.jpg?1

 

and happy

 

http://i.imgur.com/ep3e6tp.jpg?1

 

[Continue..]

Edited May 10, 2013 by cybe

[cybe]

So now I got a big pile o' shits to put back on/in/etc.

 

http://i.imgur.com/QHsaTn9.jpg?1

 

And here's work in progress:

 

http://i.imgur.com/deFu1Qp.jpg?1

 

 

I moved the Crank from the 'other' block into this one - and brought the better Pistons with it. I got three of them in yesterday and chipped a piston-ring on the last one - so here's where we take a break.

 

Disclaimer:

 

I have no idea what I'm doing, and it's probably all wrong. More to follow.

Edited May 10, 2013 by cybe

[Ackbar00]

Sell all that shit and put a LSx in it?

[cybe]

http://www.onefry.com/wp-content/uploads/2012/12/turbo-mower.jpg

 

 

Edited May 10, 2013 by cybe

[ICEMAN1647545504]

Sell all that shit and put a LSx in it?

 

Yup... Done.

[Jackson1647545504]

subscribed

[hpfiend]

nice find!

 

Best steering and 2nd best door handle pop (wierd I know- but 911 was best) of any car I have driven. I almost bought a stage 3 944 turbo (951) before the z06... sort of want one still.

 

Where did you send those parts to get that clean?

 

You may want to part it out on rennlist or ebay. There is probably more than 800 in parts there easy... but I understand wanting a project.

Edited May 10, 2013 by hpfiend

[hpfiend]

Yup... Done.

 

15-20K later....

 

 

$2,100 Base Renegade Hybrids Kit

 

$899 Radiator/Mounts/Fan/Harness

$749 Headers

$200 Ceramic Coating

$145 Remote Oil Filter Lines

$25 Coolant Temp Sending Unit

$45 Oil Pressure Sending Unit

$35 Oil Pressure Sending Unit Adaptor

$100 Kevlar Clutch Upgrade

$440 12" Flywheel and Pressure Plate

$245 LS-1 CUSTOM FUEL REGULATOR/FILTER/RETURN COMPLETE KIT: With correct fittings for your Porsche stock fuel lines.

$200 CUSTOM FUEL RAIL RETURN MODIFICATION (Customer's core needed.)

$145 SWIVEL 180-DEGREE THERMOSTAT AND HOUSING: For added frame rail clearance over stock LS-1 thermostat.

$75 CUSTOM BUILT POWER STEERING LINES:

$240 STOCK GENUINE GM LS-1 CAMARO STARTER: New

390 LS-1 COMPUTER PROGRAMMING: Available with complete emissions all the way to full race.

425 LS-1 TO 944 COMPLETE CUSTOM FUEL INJECTION HARNESS: Without emissions.

$285 LS-1/LT-1 CUSTOM CV/TRANSAXLE MOUNTED SPEED SENSOR KIT: With reluctor ring and GM plug.

$140 LS-1 COMPUTER: Programming required, core charge $250

$29 LS-1 RIGHT ANGLE INTAKE BOOT

$20 LS-1 Aluminum Intake Tubing

$85 LS-1 TO 944 Throttle Cable

$29 Heater H-Valve

$2,550 993 TT Front Brake Setup

$215 944 STOCK REPLACEMENT BRAKE MASTER CYLINDER: New

 

$2,000 2001 Camaro/Firebird LS1

$1,000 951 Transaxle w/ LSD

$550 Fiberglass Turbo Grill/Rear Spoiler

$2,000 Paint

$2,500 Misc 944 Parts

$200 951 Rear Brakes

$2,500 83.5 to 85 Porsche 944

$800 Tailpipes/Mufflers

 

$21,361.00

 

He only paid 800 vs 2500 for the car and you can probably get an 01 ls1 cheaper these days and maybe you aren't a brake freak like me ...

 

I made this list several years ago...

 

but $15-20K in an $800 car?

[ICEMAN1647545504]

You can get a wrecked Camaro for 2500-3000 and have most of the parts that you need. 8-10k for swap parts. 10-12k total investment. Just got one done. I know what they cost. But, its still cool to see them and you cant beat the performance.

[zeitgeist57]

Regardless of powertrain, I srsly approve of this project. GL with getting everything together! :thumbup:

[944s2]

This is awesome, GL!

[Toph6888]

This is a sweet build, I like when people take a shot at something and go for it with limited experience, thats how I felt with my build, and it keeps the adrenaline up!

 

Those parts you got cleaned look really good. Makes me wish I would have sent them out for the same treatment.

[Buck531]

Nice job Blake.

[cybe]

Thanks,

 

First - I totally understand the LS argument. Same weight, more powar. But if I wanted to drive a Chevy I would buy one - for now, I want to drive a shitty mid-eighties red 4 cylinder front engined excuse for a Porsche.

 

I'll be reposting my thread from the 944 board here so you have photos, but words will be out of context.

 

-------

 

I do have this problem, however:

 

http://i.imgur.com/XXDav6d.jpg?1

 

 

The place that cleaned / rebuild my parts glass-blasted this exchanger .. aaand I'm not comfortable using it, now that it's undoubtably full of blasting media.

 

Thanks for the reply!

 

The Alt, Starter, and pumps were rebuilt properly - this place did the work nicely, and will do the injectors too.

 

The parts cleaning was kind of a bonus service I tacked on -- not their usual gig, I suspect. Still, it's nice to work with clean parts - and it helped me to identify some failures I would've otherwise missed:

 

http://i.imgur.com/Ox0GDQb.jpg?1

 

My fault for not specifying about the exchanger, I expected just a parts wash.

 

 

I'll keep posting as I go The interior's "just ok" I think - I haven't spent any time inside the car really except to pull the Motronic unit.

 

What do you mean nothing special, when checking out the option codes ? You have an M456 car don't you?

 

I suppose so!

 

Means you have short, Sport Springs, adjustable Koni Sport Shocks, a lower to the ground stance, the H.D. Sport sway bars, and possibly a Sport Torsion bar set up.

 

That's good news - but I'm tossing the torsion bar for coilovers.

 

And how do you know the previous owner didn't already put in an LSD? Check to make sure, along with all the other stuff..... hopefully it still has the sport coded options. Along with the possibility of a 4 spoke Sport Steering wheel.

 

I'll check that -^I do think the wheel is four-spoked. ^I haven't spent any time inside yet .. bummer, right?!

 

Personally I would have brought the broken woodruff key problem to the machine shop too and let them monkey with it...... at least you would have kept the o.e. block with the oe numbers with the car. This block may well be the same one Porsche has a record of at the Factory on their Kardex file...... the birth certificate of your car.

 

I was *so close!* ^The other block I got from Craigslist for the crank - turns out somebody had used a ball-hone in the cylinders. ^Bad news for an alu/sil block, yes? ^I didn't use it, just the rotating assembly. ^I find it was a bonus in the end, it had new bearings and piston rings! ^Assembled, but never run or installed in the car.

 

My block is M44/07, donor M44/09

 

My original block cyls:

 

http://i.imgur.com/gxLaqlB.jpg?1

 

The ruined(?) donor block cyls:

 

http://i.imgur.com/bZibAha.jpg?1

 

Old piston (out) ^vs. new (installed)

 

http://i.imgur.com/BwLSo0Z.jpg?1

 

And do not chance running the oil cooler. Throw that thing out like yesterday and get a new one from Ian. Its shot now with the media blasting.

 

Agree - I'm looking around the local junks for a replacement. ^If I can't find one, I'll get from Ian when I order hoses, etc. ^List is nearly $500??

 

Who were these cats you brought this stuff to ? Have they no clue what they are doing spraying this media around inside starters, oil coolers and alternators ?

 

It's a good place -- been open since 1938 -- my uncle's business. ^They're excellent rebuilders, but not a repair shop and don't usually mess with this sort of thing. ^They blasted what I sent as a favor, so I really can't hold it against them. ^The starter, pumps, throttlebody and alternator are like new!

 

There is a wealth of info here to help keep you from making irreversible mistakes.

 

This is an adventure and learning experience for me. ^Thanks for the welcome, I'll have plenty to ask.

 

Today's big adventure was the clutch fork/pin combo. ^Check this out:

 

http://i.imgur.com/73xhWKc.jpg?1

 

Toast, right?

 

Hey Noah, glad you like the thread. Lots of pics

 

With any luck, I'll never see that blasted key again!

 

Thank you for the tip - my crank key is flat bottomed, I didn't have much luck with the punch method. Angle dikes did the trick on the other one.

 

 

Another view of the clutch fork pivot shaft and bearing impressions:

 

http://i.imgur.com/UMoCuDX.jpg?1

 

The bearings are in a laughable state.

[cybe]

Today, I went and picked up a replacement oil cooler.

 

Old:

 

http://i.imgur.com/Ir6D0v6.jpg?1

 

New:

 

http://i.imgur.com/aQoyR81.jpg?1

 

Put new o-rings and stuff, set it up and installed:

 

http://i.imgur.com/0JkicR0.jpg?1

 

http://i.imgur.com/I4JdOpf.jpg?1

 

http://i.imgur.com/xhfsnIz.jpg?1

 

I have the original 3-piece, o-ringless OPRV. Was in fine shape.

 

 

I guess I felt like I was on a roll, so I continued on:

 

http://i.imgur.com/op3Baw5.jpg?1

 

http://i.imgur.com/DaCb4vq.jpg?1

 

And this is where I stopped:

 

http://i.imgur.com/aSKB7pn.jpg?1

[6 Speed S4]

Lookin really good, I want to get a 951 for a project car!

[cybe]

crossposting again. somebody asked for rest-of-car pics.

 

Not much to see right now, since it's in a small garage - but here are some clues as to the car's aesthetic condition:

 

Someobdy boinked the fender, but the guts are straight I think:

 

http://i.imgur.com/8EKRQUB.jpg?1

 

This is the access panel. (heh)

 

http://i.imgur.com/90qaRTq.jpg?1

 

Hm.

 

http://i.imgur.com/eNalO1S.jpg?1

 

She's been around:

 

http://i.imgur.com/EcMwmnb.jpg?1

 

Step 1: remove steering wheel cover.. some sun fade and bolster wear.

 

http://i.imgur.com/msHfL3P.jpg?1

 

The dash is pretty good, the 4-spoke wheel is present, and the carpet is bone dry! No weird mold or anything. I removed the factory plywood (sigh) and found the motronic unit in superb condition, with only a handprint on it. Attribute this to the still-intact battery tray, right?

 

http://i.imgur.com/meT83oy.jpg?1

 

 

I found all manner of interesting things under the seat - a raffle ticket, some black eyeliner, sunflower seeds, cigarette butts. Know what I didn't find?

 

A french fry.

 

Doesn't every car on the planet have a mint condition french-fry in it somewhere?

 

Wife named the car 'Vicki,' she figures it's proper for an aquanet-soaked 80s party girl with an affinity for dark eyeliner, cigarettes and sunflower seeds.

 

This is a departure from our other cars, Inga, Helga, and Olga. Shrug.

[BigOxley]

i love the fact that someone is out there giving new life to older cars. good luck

[cybe]

Thanks man! Anybody can do it - I'm a novice.

[Smokey]

I randomly have a new upper radiator hose for a 944. Let me know if its something you'd be interested in.

 

 

Awesome project. Great to see it come back to life.

[cybe]

Hey Chris, that's awesome - I'd be happy to relieve you of it!

 

and thanks for the rep, much appreciated.

 

As far as progress update, I was pretty busy this weekend - but I took the clutch fork with me up to Byers, I have a buddy who is a tech there - we put it on the 20ton press to pop the bearings out .. and it wouldn't go. It was getting a little sketchy, and replacement forks are 300 bucks. Which is shit.

 

Awesome to see their 'special tool room' though!

 

Jaguar side pic:

 

http://i.imgur.com/Nctrsv3.jpg?1

[FourString]

Nice job so far! Like said above, it's neat to see an old car given a new life.

[cybe]

Yesterday, I got the cam box prepped/reassembled and sealed, dropped the lifters in:

 

http://i.imgur.com/Shbkm78.jpg?1

 

http://i.imgur.com/nRrfHgz.jpg?1

 

I started cleaning and inspecting some odds and ends - plastic covers, the oil separator cyclone, idle control valve.

 

http://i.imgur.com/xvSL0E1.jpg?1

 

And I got myself a little present ...

 

http://i.imgur.com/AfaXL9v.jpg?1

 

http://i.imgur.com/ZB8WeEx.jpg?1

 

15x11, 245/40/15 Pirelli P7 (15x9 fronts not pictured)

 

Unfortunately .. the offset doesn't quite work. Maybe I'll be able to flip the faces or swap to the other offset rear-end?

[CRed05]

Cool project. Those wheels are sweet too.