Ben006

thank

The steam cleaner wasn’t effective at all... even though is a huge one !
so I used professional wheel cleaner (Wurth), and various brushes...
that’s why it took me ages to get it clean !

Now I have to do the front of the engine compartement where the condenseur used to sit !

fatmanontwowheels

Cool, thanks! Wurth has some good stuff.

Ben006

Crankshaft position sensor prototypes :




Still has to improve the design to position the sensor precisely over the trigger wheel.
I don't know yet if I'm going to have it made out of nylon, or aluminum...

I started to look at how I'm going to mount the seats.
It should be too hard, the factory seat mounting holes will line up with sparco universal seat rails, I just need to make a mount to put the seat on to the rail.
I'm sur factory Lotus mount could work... but I wan to make them myself, and they will cost half the price of factory seat mounts.



I had never welded with shielding gas before, it's not perfect, but it penetrated deep enough to make this a strong weld.
And I still have to time to practice before making the final mounts.


Here's a crappy photo showing nothing of what it'll actually be like ! Don't thank me...



Unrelated pictures :
The new version of my 986 Plenum, with a factory style quick disconnect fitting.



And the 996 version !




I've got some 991 GT3 RS PFC floating discs... but at 380mm diameter they will never fit on the 928...
But I really like the spirolock they used to secure the disc to the hat ! Serves as a spring to quieten the system too and takes a few seconds to remove the disc from the hat VS forever with a conventional system !




Ben.

Bigfoot928

pretty cool progress.

Ben006

Eheheh

That will looks so good on the finished engine !!

Though... the machining I did is not up to my standards... and the tools needed to make it right are expensive... so I might just have the final rails made :/

Seat is almost in !


When I'm back from vacations I'll have the side support laser cut and I'll weld them. It's propably the easiest part of the whole project so far !

While I'm at it, I might have the CKPS support made that way too.

I have to find the correct wiring harness to hook up the new fuse holder from this mess...


And now I have to find and replace the bearing that should be there...



I stated to strip the back half of the interior too.
Saving weight saving weight...

Hey_Allen

For finishing up the bores on the fuel rail, what tooling are you using?
I choked on the cost of buying a $130 "injector port cutter" tool from Ross Machine Racing, but did find out that you can go a LOT cheaper by drilling to ~13mm, and then using a 14mm reamer to bring it up to diameter.
My process was to drill the center hole that will allow fuel flow, then work up to about 1/2" while stopping short of punching all the way into the fuel passage.
Break the edge with a counter-sink or even a router bit, and then ream it to final diameter with a 14mm fluted reamer that I purchased for the job.

If you want to do it this way, just make sure how much runout your tooling has, as a 1/2" drill might be over 14mm with a little bit of runout. Testing on an off-cut or scrap first is cheap insurance.

Ben006

Hi guys !

After going on vacations and being stuck three days because of cyclone Calvinia, I'm back !


Before leaving, I planned a lot of things for the 928.

First thing, as I said, is getting fuel rails made... I decided not to use home made ones for safety.
So I asked Nuke Performance if they could make me some !
And ... well, they can ! For a very faire price actually ! 239€ for the two. But if some of you want some we can get them cheaper !
Here is the fuel rails for the S65 V8 engine that look the closer to the future 928 rails !
https://www.nukeperformance.com/prod...category_id=69
I will start a new thread to ask if anyone's interested

I finished the CPS mounting bracket prototype, after 6 iteration I got it right.
It's not going to be 3D printed, it's going to be laser cut aluminum and bent at the end, because this is cheaper in the end !
And since I'm going to have to make at least 10, anyone who will need one will have one

The same company will cut me some lotus elise seat brackets too !

I need to gather some money and get all the remaining parts to at least start the car before the summer !

By the way, does anyone know about this and if it's still possible to get some ?
http://forums.pelicanparts.com/porsc...8-ready-3.html

Ben006

Got a 928 in the shop on Tuesday !






I love the color !
It motivates me to finish mine !

karl ruiter

I think that if you can get a whole kit together to convert a CIS car to EFI with the cpu, your cool intake, fuel rails, cps bracket, etc that there might be a market for it. It might be a little limited due to emissions requirements in many locations, but still there are folks who are unhappy with CIS and don't want to tackle the conversion process from scratch. You might not have to provide the actual electronics, so much as point to a vendor and supply the customized maps.

Ben006

It's been in my mind since day one

We'll once the car is running !
For now it's my priority.

I received some good stuff this week !









I also received my reamer for the intake runners ! Works perfectly, the injector is sitting perfectly !




I should receive some really good stuff from 928Motorsport and Mishimoto next week !

Ben006

Update !

I received a big package !

Mishimoto fans:


Mishimoto oil cooler :


With lines :



And the HUGE circle track radiator :



It's a tight fit...



Slightly taller...



The power steering reservoir is in front of the radiator outlet... but I can always move it, and I plan on going electric power steering pump in the future.

I tried the set in the car with the rails !

It's perfect, the position is exactly what I wanted ! No need to move anything !

I might have screwed up the steering column bearing install...
...
...
...



I started painting some parts, and receiving the connectors for the wiring harness too !

Ben

Ben006

Ben006

So, I worked a bit on the 928 today !
Fixing the bad aluminum parts to make thm smooth again !



Ditched the A/C lines !


Then I started to play with the new standalone ECU, and I wanted to see what the new harness could look like !
But first, I wanted to clean up the old harness...
I disconnected the whole front half of the car, and now I'll be removing every wire and connector I don't use.




I should receive the 928 motorsport order, and the Pro Speed Parts order early this week !
Then the fuel rails !




Ben

Ben006

Sooooo...

Ok, confinement update !
I've been working on the car for the last two weeks !
I made HUGE progress ! If I had my fuel rails I could even have started the engine !

First, I might end up not using the 80mm TB, and use this 92 instead, it looks better, with the integrated IAC valve... problem, this IAC valve is controlled with a H bridge... my ECU can't control it... So for now i'll stick with the one I have and an external IAC valve.




Next to it is a GT3 82mm TB !

I've received the 928 motorsport aluminum reservoir too.


And AN fittings for the fuel system!


With the right tools... I'm still waiting on the soft vice jaw special for AN fittings.


Follow up in 10minutes !

Ben006

So, I got the harness out, and I'm removing everything related to the engine as I won't need it anymore. And I also checked everything.


I'm also redoing the charging and starting harness.



Looks like I messed up the alternator... got the wrong one ^^
I'll adapt it, no prob.

I started to clean the underside of the engine too.

There is still much cleaning to do !

I need to remove the exhaust to fit the O2 sensor bung.


Here is how i'm going to run the oil cooling lines :

Y'a du mou...






Tadah