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944 Turbo S - Project Time


eldavo69
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  Tipex said:
Cage and harnesses together, no problem, never one without the other though, and don't forget to fit padding to the cage, it'll be harder when your head bounces off it than the cars standard interior!

Yes, this +++

You'd be amazed where you can go in an accident. I know of someone in a crash (yes, a Caterham, in a race, no, not me) whose head went into the passenger footwell.

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  eldavo69 said:
Popped back to Lexus this morning.

Had a nice coffee, thumbed through Top Gear magazine and ogled the cute receptionist (shame the last two weren't the other way around).

15 minutes later and I had this year's MOT - woohoo.

If I get either of the 2 jobs I've gone for... I'm going to try to wangle a CT200h or the new IS300h. At around £100 / month to tax, they're 600 quid a year cheaper than a 320ed.

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Look what the delivery guy brought me today:

mude7ary.jpg

Won't be going in just yet though. Seats will have to come out to fit it and the trim guy is carpeting the rear squab for me soon (hopefully) so I may as well wait until that is done as it'd only have to come back out along with the seats again.

I've been chasing down a couple of coolant issues first before I start bolting go-faster bits on and turning the boost up. The turbo has an auxiliary water pump that runs after the engine is turned off or when the turbo gets a bit hot. It had a slight leak from the housing around the impeller so I pulled it out, stripped it down and resealed/rebuilt it before putting it back in this hole:

dypusuvy.jpg

Car was running hot as well, so I pulled the pipes off the water pump and removed the thermostat. It was rated at 88 degrees but didn't open fully until the water reached 100 degrees when I boiled it in a pan (when Mrs Eldavo wasn't in). Replaced it with a new part rate at 83 degrees that opens when it should so car is now running at a more sensible temperature. Still a slight leak from the thermoswitch that controls the fans but I've removed it, replaced the gasket and a missing o-ring that the nice man in Halfords let me have for nowt :) and hopefully when I put it back in tomorrow it'll be sorted.

Just for Chris and his tally; £175 delivered for the cage, £14 on a thermostat and the carpet will be 2 metres at £50 per metre and £30 to fit.

Edited by eldavo69
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David, my question about cost wasn't meant to seem like I'm Ian C's apprentice. It was more to prove that via the accident and hard rebuild graft, you have ended up in the fantastic position of a bespoke road and track toy for modest cost.

It sort of proves that such stuff can be done at a normal mans type budget, thus proving that tens of 1000's isn't the main requirement, effort and desire is +++

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If you look at the cage, that's how it would look from the front of the car. The bars on either side pointing towards the camera bolt into the B pillars and the ones pointing away bolt into the C pillars. The two plates at the bottom sit over the side of the rear squab and the vertical part of the plate has a hole in it, this corresponds to the lap belt attachment point for the rear seats and is where my eyebolts are currently fitted.

So it is designed to fit over the carpets in this way. Other bars/cages I looked at that mounted in the same way didn't have the locating plates around the mount points.

Edit: - Don't worry Chris I know you weren't costing up the build ;) it's amazing what effect man-maths has on everything though, I've simply not included the odd £20 on coolant or £10 here and there on little bits and bobs like trim pieces, tools, etc.

Edited by eldavo69
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Bugger. Temperature gauge now showing the engine running at the right temperature as the new thermostat does its job.

Fan switch still leaking slightly from the gasket, spoke to a Porsche mechanic and he said change the gasket and it'll be fine. 19p for a new gasket from Porsche (18p after discount, every little helps).

Put it on and tightened the switch up, but noticed as I tightened it snug, the plastic surrounding it was slightly cracked and was opening a little as I got near my intended torque setting.

Swore. Loudly.

Pulled the radiator, am now sick of the taste of coolant from it sploshing in my face like a scene from one of Bangle's special films and how ill it makes you feel. Radiator is nearly 25 years old an won't be at its best anyway so if I'm going to turn the wick up a little it's best to replace it with a new one now.

Hmmm, £550 from Porsche explains why they command £75-£100 used. Ordered one from a local radiator place for just under £200 beating all the Internet prices I could find :)

Pick it up tomorrow and then not a big job to fit it (he says).

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Collected my new radiator to find it was made by the same company as the original. Furthermore it had the Porsche logo and part numbers on it too, well it sort of did as someone had made a half-arsed attempt to grind them off.

So a genuine Porsche radiator at less than half the price of one - happy days!!!

So I took one radiator-shaped hole:

egu6ymyp.jpg

Added a new radiator:

5ygejeqy.jpg

And after a bit of spannering:

ujyduqe7.jpg

Then fans back on, undertrays on and then out of the garage for a wash in the sunshine :)

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I shall be spannering the Galaxy in the sunshine tomorrow, only a service, but I can do the whole lot, including pollen and fuel filter, for about £45, and I quite enjoy doing it on a nice day.

Oh, and I need to bleed the brakes too, run out of time when I changed the pads a few weeks back.

Which reminds me, I need to pick up new bleed nipples for the rear callipers as they'd rusted so badly the spanner wouldn't grip them!

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Ticked a couple more things off the to-do list this week!

The carbon door cards are screwed in around the edge but they rattle around in the middle. I didn't want to drill more holes in them and the door so I got some self-adhesive insulation foam and got to work making "Tron" doors:

etabahen.jpg

It was also a good time to put the RS-style door pulls on using the seatbelt fabric Mook kindly sent me.

Cut a hole for the slot and screwed the 964RS covers into place.

We come in peace earthling:

yda7uhud.jpg

And then all reassembled with the pulls bolted to the door:

qepu6ysy.jpg

6etezuvu.jpg

Trim guy is coming to fit my rear carpet at the end of the week so I put some spare sound deadening down over the transaxle. I figured the slight bit of weight was well worth the decrease in noise and increased cabin comfort:

2epa6uva.jpg

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