Carpokes Porsche Forum

Transaxle is out and has been shipped off with the OS Giken LSD for a rebuild. Sean Buchanan has been really great to deal with, hopefully the pinion bearings and syncros/selectors are ok and its only the diff bearings that need attention.
Engine mount got the Urethane treatment, Im a little worried Ive gone a bit overboard with it but I guess well see when its back in the car
TT has been stripped and is getting sandblasted before getting some gussets welded in along the split. The bearings in there were probably ok but the front bearing moved quite easily while trying to remove the shaft so it wasn't far away from failing. The split was 2mm wider in the middle but we found some heavy duty Tilton hose clamps closed this up quite easily. Ill probably start a seperate post on the process we used to rebuild the S2 TT once I get it back from sandblasting.

It begins!

Spark plug extensions to help make a proper connection with the VAG COPs New bellhousing arrived and sent off for vapour blasting, the once I bought previously wasnt from a Turbo as advertised I went a bit wild with Zircoflex heat sheild this week. It doens like bending two ways at once which caused a few creases and lead to the need for some separate panels on the more complex curves.

Nice work Luke! I like the spark plug extensions! I used some simple m4 hex extenders but this is far better!

BasHenneman wrote: Fri Nov 15, 2024 11:29 pm Nice work Luke! I like the spark plug extensions! I used some simple m4 hex extenders but this is far better!

Cheers Bas, I found them on eBay
https://www.ebay.com.au/itm/18525703710 ... media=COPY

Transaxle is done and about to make the 4000km journey home.

https://www.facebook.com/share/p/eJkJwnCkqgrUfyrY/

TT is ready for reassembly
All I am waiting for now is an oil pickup which is lost in a customs vortex and my fabricator to start the crossover pipe.

Just found this build thread and then noticed it was a year old, so wondering is the beast all back together and assaulting the asphalt now?! Great pics showing the build process, which is always fun for others to see regardless of what Porsche they own, since there always seem to be ideas that transfer over to many models.

WillyDaP wrote: Sun Dec 01, 2024 3:29 am Just found this build thread and then noticed it was a year old, so wondering is the beast all back together and assaulting the asphalt now?! Great pics showing the build process, which is always fun for others to see regardless of what Porsche they own, since there always seem to be ideas that transfer over to many models.

Thanks for the kind words. The thread is a year old but the project is over two, unfortunately the car is in 1000 pieces at the moment because I've been let down by a few people over the last 3 months, my plater had a breakdown when I asked about progress and handed my parts back. Then my fabricator who was working on my crossover has had his rent doubled and is in the progress of moving for the second time this year so he's not working on anything else until next year. I've bought a kit to do my own zinc plating so the last few brackets and heatshields should be done shortly but its basically impossible to get another fabricator to start on my crossover at this time of the year.

I have a rebuilt gearbox, TT ready to go, the motor will be finished once the plating is done but I'm hesitant to put it in until I have the crossover sorted, just in case the fabricator wants the motor to help mock everything up.

Thanks for the update and I know I and others will be interested to see if you are able to get everything up and running in 2025. Have a great Christmas, Hanukkah, Kwanza, Boxer Day, etc., ha!

Well I've had some good news for once, we found a welder who specialises in exotic alloys who is confident he will have some success repairing my cross over cracks. Apparently heat treating before welding is the key, if this works it will buy me some time to get the car running until I can get something fabricated.

New oil pickup arrived (not sure I needed it but its cheap insurance) The sump is finally on and timing/balance belts all done. It took a little while to get our heads around timing the 968 cams but we got there in the end.
Rebuilt intermediate steering shaft arrived from JMG in the UK, added a little heat protection because these sit about 10mm from the headers in the RHD car. I didnt realise how much play mine had until the new one arrived.