911 Carrera RallyCross Project

10 minute(s) of a 245 minute read

I thought we hadn't done much to the car recently then I looked at my pictures in my phone and thought "oh poop, better do an update". So here it is:

Removed the rockers for weight savings and bad-arse look.




Then thought. I need a bad-arse helmet too:

1


Then we took some cars to some coffee (cars & coffee)


RallyCross in South Lyon this weekend . Let's see how the new helmet performs.

5-25-2014

Sent the car on a diet again. Removed antenna:

added a foot rest, removed front carpets, removed sound deadening, removed center console, removed ac blower:









The result, -52lbs:




Also adjusted the valves on the right side of the engine, tried to adjust the clutch but I think we need a new helper spring. Adjusted the handbrake.

6-3-2014

Well, it finally happened; the RallyCross 911 got beaten in a RallyCross! So now it's for sale. Nah, we're keeping it silly. It did get beaten though but we have an excuse as the clutch was slipping. At least that's Scott's excuse. My excuse was slipping talent. Here's a video of it launching with the slipping clutch. We thought it was tire spin but tires don't smell like that PU.

So do we need a new clutch? We're not sure. The clutch disc was changed last year even though the old one was only 50% gone, but the pedal has felt funny the last few weeks. We thought it was our inability to adjust it properly but upon closer inspection we discovered the helper spring, the horse hoe shaped one under the transmission was binding and possibly taking some pressure off the clutch plate. It also stopped the clutch pedal from coming back up all the way too. That's all freed up now and it seems to be working but we need to test it under race conditions to be sure. Fortunately there's an autocross own the street this Sunday that will be perfect for such an occasion.

Other than this hiccup we finished cleaning up and painting the driver's side floor which meant dealing with the ECU, handbrake and gear stick.






Just need to source a better pedal plate and passenger footrest. The wooden ones fell apart.

6-4-2014

Some pictures from the last RallyCross courtesy of Nathan Usher.

6-19-2014

A bit of fixing, a bit of improving, then BAM! a whole lot of broken, probably.

We went to adjust the loose wheel bearing last week, the day before the autocross, only to find it was a worn tie rod end instead. Skipped the autocross and ordered up some Turbo tie rods from Pelican. These are what came out. What were you thinking Dr. Porsche?



and the new stuff. An "upgrade" to what every other car manufacturer uses.



Pretty easy to swap in. The hardest part is getting the spring to seat over the bellows but we found rotating the bellows also rotated the unseated portion of the spring.







We then sent the car off to the 944FEST to be used for rally demo runs while we visited Niagara Falls with the family. By all accounts it was a big hit. We picked up the car from the venue on Tuesday and took advantage by doing some practice runs for a couple of hours. Unfortunately during this session the gearbox started acting up such that now it won't go into first gear and fifth is a bit stiff to get into as is reverse. We have yet to get into it but suspect broken synchros but hoping for something in the linkage.

8-4-2014

Hey, I need to apologize.

Apologize for not updating this thread for a while, I have an excuse: I broke the car. That's not really a good excuse. I could have posted about how I broke the car. Well, I was going to but I realized pretty quickly that I didn't need to race the rest of the year and so I didn't need to fix the car right away so I decided to fix my UR Quattro instead as it hasn't ran for ten months and THEN I forgot to update this thread. Forgive me now?



85 UR quattro - AudiForums.com



So what happened to the Porsche? Well, I think I broke the gearbox during a testing session. It will no longer go into first. There's no grinding or weird feelings. It just wont go in. I don't think I should force it. First was always a bit grindy and we did find some dog teeth on the drain plug last summer if you remember.


During the test session I started using first on one particularly slow corner and it would grind sometimes. Then it grinded a little more then the next time I came round it wouldn't go in. All the other gears work though fifth was very stiff at one point and I couldn't get it out of reverse a couple of times. It's out now and fifth and reverse all work fine.

So what have I done and what's the way forward if you excuse the pun?

11-9-2014

The Porsche's new home is finished.




and a friend to keep it company

12-21-2014

Took the engine and transmission out. Time to fix the transmission.






So, what do I do now?

12-28-2014

Gearbox came apart quite nicely. No horror stories so far. Just a broken synchro ring and stripped dog teeth. The great news is the main bearing races are not loose in the diff housing and no gears look chewed up. I think we will be rebuilding this one