356 Speedster Flat6 outlaw build

[greg356a]

Ok, pics as mentioned







Hopefully all will go together

[Hebster52]

Cool pedal!

Hmm. What is all the blurring about on the intermeccanica widebody photos...?

[KS]

Cool pedal!

Hmm. What is all the blurring about on the intermeccanica widebody photos...?

Removal of the word 'Porsche' in photos - in the same way that Singer don't want you to refer to their 911 as a 'Singer Porsche', other companies are concerned about Porsche pursuing them for 'passing off'.

[greg356a]

Totally correct KS
I understand that as an owner/ builder you can use the original badging without fear of recourse by Porsche. I hope

[mdmax72]

What's the pedal from Greg??

[greg356a]

Rich, nothing special really, just off the shelf via the web which I have then heavily modified to fit the space and work correctly then sent off for powder coating.

[mdmax72]

A lot of work gone in to it, hats off.

[greg356a]

Long day of backward steps yesterday. I thought the clutch was ok, turns out the flywheel had some heavy scoring and maybe the oil crank rear seal should have been replaced and I also wanted to get another fixing on the fuel line but the engine was in the way.

So nothing for it but pull the engine and transmission out and split them to have another look. Upside, easy to pull the engine out due to all the original build/ prep work (designed for easy future maintenance). Downside I have ordered Flywheel, clutch set and a new oil seal, ouch!

So fingers crossed next Friday assuming parts arrive all goes back in and maybe see it moving under its own power for the first time.Well its great to dream!

[greg356a]

Ok, so it's a week later, all the clutch parts arrived on time and they are all correct. Started early, things going well. Crunch, 12mm flywheel bolt shears when torquing back up. Bugger! Chased around and cant find a replacement anywhere local. Nothing for it ordered the parts and schedule another day to try again.

[mdmax72]

Greg I'm putting oil cooler up from on mine and wondered what size oil cooler your running. Just give me an idea of size.

Did the bolt snap in the crank?? Was you able to get it out ok?

[greg356a]

Morning Rich, I used a oil cooler from a 1985 911 and a thermostat from a 1986 944. It has these huge oil pipes which maybe too big for any VW connection. The cooler is approx 330x150mm. I am using a smaller cooler on my 1776 type 1 which except for a 30 degree sunny day runs too cold, but I have not fitted a thermostat yet.

Managed to get the flywheel bolt out by welding another on the end. A new bolt is an unbelievable £10 each.

[mdmax72]

Cheers Greg,

sounds like you had a lucky escape with the broken bolt. £10 a bolt eh, just needs a nut to to buy one

[greg356a]

The annoying bolt now in the bin! Spent yesterday working on going forward again. The clutch and flywheel fitted and torqued down to the numbers in the book. The transmission was offered to the engine and eventually slid back on with some persuasion . The whole unit was then lifted and bolted back in place. Remembered to fit the rear engine tray after the exhaust so did the exhaust twice. fuel, oil, accelerator cable fitted. So big step forward.
I still have a problem with the hydraulic clutch conversion not working. Took the 993/964 master clutch cylinder apart which appears ok, but when you pump the pedal no movement at the slave. The master cylinder is probably 20 years + old so doubtful if working correctly. Pushing the plunger in by hand does not give much force at the other. Going to try a new master cylinder to see if that works.

[mdmax72]

Still take the old master cylinder apart to see if the seals have perished just for piece of mind, although I'd of thought you'd be getting fluid spilling out of the master cylinder itself if they are shot. Maybe the problem is elsewhere??

[greg356a]

Hi Rich,
The neoprene seals looked okish, there was some crud around the back of them, bore looked smooth. Just when you put your finger over the outlet and compressed the plunger no real force was built up, certainly not enough to force your finger off. Looked back through the mods on 914 world, again seems to be a relatively common approach to use 993/964 pedal assembly and master cylinder and a wilwood pull slave cylinder. I have used new flexi hydraulic pipe with correct fitting. Maybe flexing in the wall could be a problem. If after fitting a new master cylinder I have the same issue will try a solid pipe. After that its combination of different bore sizes I guess, may have to get the calculator out and see what I need. I took the whole pedal assembly out on Friday and yesterday made sure everything went back correctly. Also fitted new rubbers to the pedals and a brake return spring.
I have Thursday off to have another go, fingers crossed.