Chads996

I have not posted in here for a while. And all this time, it has been gradually worked as J3 has been restructuring. Todd Ketchum has been the mechanic on this project and has done simply artful welding on this car. Based on all the work and what has been done, I think I will write an article about the build and what has gone into making this car what it is.

As of today 05/21/09 the following has been completed:

Interior & Safety:
- Interior gutted, cleaned and repainted.
- Custom center console installed
- Momo Suede racing wheel installed
- Fire extinguisher mounted
- Custom LTW door panels fabricated and installed
- Sparco Evo 2 L (x2) with BK brackets installed
- Custom 4 point roll car installed (likely going to be completed to full cage next year)
- Sunroof mechanism removed and panel fixed in place
- Custom aluminum racing pedals from SRP racing


Exterior & Suspension:
- Combination of 996 & Boxster twists painted and installed (8.5x17 & 9x17)
- front fenders replaced with CF panels and painted to match car.
- Front splitter courtesy of CPR
- Ground control double adjustable front coilover struts with single adjustable rears (Koni) (rear torsion bars removed)
- 500# front & 600# rear springs
- 968 M030 adjustable sway bars with custom drop links
- Complete Poly & delrin bushings front and rear
- Front BK strut brace with Ground Control camber plates


Engine & Drivetrain:
- S2 engine replaced with a 1995 968 motor
- Crank scraper installed
- Custom oil pan baffle
- Reinforced the oil pickup tube
- Rod bearings replaced
- new spark plugs
- New cap & rotor
- New plug wires
- Checked cam chain, tensioner and pads
- Misc seals replaced
- Replaced waterpump, belts, rollers, etc.
- S2 Flywheel and damper installed
- New Clutch and associated components
- replaced 147K torque tube with 60K S2 tube
- Solid transmission mount installed
- New shifter mechanism (trans side)
- Swapped out S2 5th gear for shorter Turbo 5th
- Replaced both drive axles and CV's
- 3" x 24" custom oil cooler installed
- Racer's Edge 968/S2 headers installed
- Custom 2.5" to 3" exhaust (Hooker Racing Muffler)
- Custom intake tubing


Brakes:
- Stock S2 brakes (front and rear) with new SS lines and PFC 97 pads
(I am going to try these as the weight of the car is significantly less than stock)



Here are some photos of the progress:

Larry Herman

Looks very nice Chad. I didn't know that you were a plus size!

IcemanG17

A couple thoughts....

Since 944-951-968's all share the same oiling issues the 928 does....you might want to consider an accusump and possibly an outboard cooler..... Also how is the crankcase breather on the 944S2...if its anything like the 928, its horribly undersized....

After almost destroying my track 928's #6 rod bearing....I addressed all of the oiling issues....you are already ahead of the game with new rod bearings ( I should have done THAT)....I hope they are the "loose" side of spec....I've heard you don't want rod bearings tighter than .002"....with .0025+" better...especially on #2

Overall the car looks great and I'm sure you'll have FUN...BUT you don't want to be like me and nearly smoke a motor on your 6th track day :>(

Todsimpson

The inner trailing arm mount should be either a monoball or a rubber mount to allow for camber and toe adjustments.

You've got a rigid bushing in there now?

Love the dash and tunnel area...clean and to the point.

APKhaos

Sweet work. You're going to enjoy this car, man. The S2's are sneaky quick. Good drivers in S2s used to give me hell in 944SuperCup!

mkd944

Especially S2's with 968 motors...very nice!

chrisc

The light-weight racing muffler attachment system is way-cool!!

Chads996

Thanks Chris. I saw your car at the shop. Wheels look GREAT!

C.

chrisc

Billy Williams PC'd them for me, same people who did the bar. Todd is installing my Rennbay belt & giving the car it's one year, 367 mile check up if he ever finishes your ride...... Hey, got an idea! If he finishes your car prior to the June DE and mine is still not ready I will be glad to use your car since you aren't registered. Whatta ya say, deal???

earlyapex

You've got a great looking car! Looks fun to drive! What series will you run in?

Chads996

Now that is a GREAT deal. LOL...

If there is a good chance that car will be done by the DE, I may sign up. I believe there are still a few spots open.

C.

shmark

Obviously you have never met Chad.

chrisc

Suggest you do it today regardless. There's a wait list for all groups but only 1 each wait lister shown for group 2 & 3. Four looks slammed. I think BMW July 4th weekend has some space.

carreracoupe997

I know the last post was 7 months ago but I was searching build photos to come up with ideas and came across this one. Please notice the photo of the rear coil-over. Does something look strange to anyone other than me?

krystar

looks non-orig. an extension inward of the original bottom mount point.