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01117 / Restoration / Phase II / Engine & front Suspension

 
Old 01-29-2019, 07:06 PM
  #46  
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Subscribed , Great job Bro !
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Old 01-29-2019, 11:05 PM
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Yo! Good to see you check in. This one is moving along a good clip. Stop by while its in 9,345 pieces!

Last edited by mit Wasser; 01-30-2019 at 07:27 PM.
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Old 01-30-2019, 12:33 PM
  #48  
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Default Progress Report on the Transaxle rebuild / Final assembly

California Motorsports is now preparing for final assembly. I am particularly excited about the surface finish on the case. Different that the head gasket discussion..... I decided to go in deeper WYAIT with new bearing$ and all (5) new sychros. Included in this project is the rebuilt of the LSD core provided by 928 Intl. (thank you Mark).





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Old 01-31-2019, 04:02 PM
  #49  
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Default Tensioner concerns

I am resealing and cleaning the original TB tensioner. The prior owner had placed a nylon washer between the lock nut and the body in an attempt to stop the leakage. Nylon does not like being compressed for more than 5 minutes at ambient. So see below attached attempt to fix. The tensioner is full of oil and so far, no leaks.


Metric High-Pressure-Rated Metal-Bonded Sealing Washers $7.75 for a five pack. part no. at McMaster Carr is:

93786A200

Able to withstand pressure greater than 7,000 psi, these one-piece bonded washers create the tightest seals. They are zinc-plated steel for corrosion resistance in wet environments. The Buna-N rubber seal has excellent abrasion resistance and good oil,weather, and chemical resistance. Washers are reusable.
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Old 02-03-2019, 01:44 PM
  #50  
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Default 01117 Body Harness Jacketing repair

The Prior Prior owner of 01117 had cut open the forward body harness to get access to individual wires.

Mark at 928 Int'l was kind enough to discount a similar vintage harness that had been molested. Same olive green. This donor had long sections, still ply-able that would make an ideal cover to the opened sections on the car.

I experimented with a few PVC glues and the final solution for adhesive turned out to be Testor's model airplane glue. While wet on both surfaces, place the 'patch' section and immediately wrap in tape. Very tightly. Let it dry for a day.

I am almost done with this donor harness. If someone else on the 928 forum has a similar issue, I am happy to send a patch section to them for the cost of packaging and postage.

See attached results

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Old 02-03-2019, 01:55 PM
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Another productive week with assembly on Phase II. Rob provided the precision tensioner tool and expertise. William provided the 5x experience of only using a Porsche OEM timing belt.



djustment nailed the number. Front suspension in and loosely fitted. Next week is fitting all the driven pumps.

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Old 02-03-2019, 03:48 PM
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Old 02-05-2019, 07:15 PM
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Default Transaxle is done / A quiz for the hardcore 928 experts

California Motorsports Inc. finished the rebuild on the transaxle and LSD unit. Quiz: besides the safety wire on the shift forks, what is the one item that is not stock on this gearbox?




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Old 02-05-2019, 08:24 PM
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nuts and studs on the differential cover rather that hex bolts
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Old 02-05-2019, 08:28 PM
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Originally Posted by worf928 View Post
nuts and studs on the differential cover rather that hex bolts
those are stock on the early boxes
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Old 02-05-2019, 09:09 PM
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Hi mit Wasser,
Great job on restoring this '78!

Please tell me more about your choices on front springs and shocks. You're moving from the original/nonadjustable fronts to a later setup? What year setup and which springs and shocks did you choose, and why?

I'm evaluating whether to move to a later adjustable front setup on my '83, because it's too low on all original springs and shocks, or put in new original front springs and replacing all shocks -- or even just all new shocks. The problem with moving to a later setup is that the '84 (adjustable type) springs are NLA and the '85 and later setups are for heavier 32V engines. Additionally, I don't know whether a later front spring setup would be an optimal match with my original rear spring setup!

Would be interested in your feedback and what you decided to do.
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Old 02-05-2019, 10:18 PM
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Originally Posted by Mark Anderson View Post
those are stock on the early boxes
LOL. I lose.
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Old 02-05-2019, 10:55 PM
  #58  
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Good eye -added spring is correct. I added it after driving the original design that flopped from side to side. This was a haunting sensation from years ago when I owned 914's and totally detested the dead feeling of the gearshift lever / linkage. I like this solution. It is a well engineered example of Porsche evolution.
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Old 02-06-2019, 12:39 AM
  #59  
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Hello RJTW,
Thanks for your kind words. Regarding the front spring swap, it is too early to say. It won't be until a week or so after it is settled on the ground. This is an experiment, I've set my blue stripe springs and perches aside for archiving to stay with the car. Three parts were changed, all from a '84 (the threaded ring, the lower perch and the brown stripe springs). I can send you part no.s if you want them. These replacement springs are not much stiffer 252 lb / ft vs. the blues at 246 lb / ft. The big difference is the free height -the 'new' ones are 1 inch lower (365mm-340mm). The wire diameter of the new springs is slightly thinner at 14.8mm vs. 14.5mm on these new experimental springs. (Above data compliments of Rob Edwards)

My '78 is a late production and already had the yellow springs that are substantially stiffer than early (green) springs. Mine are double yellow stripes at 171 lb ft vs early 78s that were a gooshy 119 lb. ft.

My goal in doing all this is to lower the front of the car, ever so slightly from the stock ride height. One half inch lower is an enormous number in this world. Goal is to creep back up on the front original height while being able to control all four corners. I love fully adjustable suspensions and 928's are a dream!

How it all comes together in terms of balance? Who knows..... I will be more than happy to keep you informed. Stay tuned!
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Old 02-06-2019, 02:03 PM
  #60  
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Originally Posted by GregBBRD View Post


The "extra" spring pressure required to move the gearshifter over to the 2nd and 3rd gear plane made the "feel" of moving too far to the right into the 1st and reverse too vague...and common.
Destruction of reverse gears and first gear synchos (and brake bands) became commonplace.

....not even close to their best engineering, but certainly an "evolution"!

Once you've actually driven this "transmission" a few miles....and you think about it....."centering" in the 2nd and 3rd plane is a huge improvement.


What aftermarket spring set is available to get that centering effect? I am too late for this because the drivetrain is already up there and no intention to lower it again. But just in case I have to do it all over again...
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