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> All the cool kids are doing it..., Low budget progress thread (Slow Race prep.)
BMXerror
post Sep 17 2007, 09:42 PM
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From: Hesperia Ca
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Well, with all the work that I'm doing to my car lately, I might as well start my own progress thread.
Backstory
I bought 4702912742 from my pops about a year and a half ago for $600 dollars, but it wasn't a steal. It had been sitting for about five years and needed a lot of work. He A couple years later he had been looking for a teener for a little while and picked this one up cheap at a dealership in Pomona Ca. He drove it for a while, but it had tons of problems, and soon he decided to sell it. However, the person who test drove it blew first gear, and out to the back yard it was sent.
Fast forward five years to when I was financially ready to get a car to start racing. Long story short, after deciding that I wanted the 914 instead of an older Miata, I told him I was interested. He said that if I bought him a set of mufflers for his bike, we'd call it even.
After that I spent about another 4K just getting it drivable. I replace all four rotors, rebuilt all four calipers, replace the brake lines with braided steel, replaced the hard lines that I broke, replaced the master cylinder, resealed the motor (after my socket and extension locked the motor up), bought two trannies for it (the first one was no good), put a new clutch and pilot bearing in it, put new rubber on the ground (Khumos), fixed and lubed all kinds of latches and hinges to be able to get into all the various compartments, replaced most of the vacuum lines and fuel lines.... the list goes on.
These were all just stock replacements to get it running well. I further had to fight with the injection system for a few months until I figured out that I had it hooked up wrong. (IMG:style_emoticons/default/headbang.gif) Of course, this is the very abbreviated version of the story. As anyone with one of these things knows, the words it takes to describe what parts you changed don't even come close to showing the blood, sweat, and yes, sometimes tears that you put into your work. But anyways, it is running decent now (the motor is still a little tired) so it's time to do some improvements. After all, racing is what I bought the thing for. So I'll try to bring anyone who cares up to date on some of the things I've been working on.
Mark D.
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BMXerror
post Jan 26 2011, 11:07 PM
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*If you don't want to read my lame story, skip the next 4 paragraphs*

Good lord! I can't believe it's been a year and a half since I posted any progress... haven't really made much, is why. Where to start?.... Well, I started autocrossing with SCCA in may of '09 and quickly learned how slow my car and myself really are amidst a competitive group. As discouraged as I was, I realized that that's where I needed to be to improve my skills, both on the driving and preparation side. However, I ended up focusing a lot of my money and efforts into track time, and little got done with the car.
About May of 2010, the D-jet system really started getting bad. It was never really great with the modified engine, but the system started deteriorating rapidly to where it barely wanted to run. I decided to park it before it cost me an engine. I quickly realized I was faced with two options. Either spend to rebuild the ignition and injection systems and live with D-jet for even longer, or bite the bullet and go to SDS as I've wanted to do for years. Well, there was no cash for that. I was trying to buy a house, and my commuter car blew an engine shortly thereafter.
However, in August I was able to find a brand new SDS EM4-4F system (exactly what I wanted) on eBay for cheap. It was a guy in Australia who bought it for a project that never got that far. With shipping back to the US I paid $1140. Plus I had to ship it to SDS and have some rework done for some of the options I wanted, as well as a V17 chip upgrade. That was another $388. All in all, I figure I saved about $500 on a fully loaded system.
Of course, as life goes, I got my house the very next month, and for a while it was very hard to find time and money to put into the install. However, I was try to spend one extra night a week in the machine shop building the brackets and stuff I need for the sensors and injectors. So anyways, in the past 4 or so months, this is what I've come up with.

The first custom part I machined is a mount for the TPS. Luckily, the 'D' pattern on the TPS is the same as the stock shaft. The shaft did need to be cut shorter, which took me about two minutes with an angle grinder and a cutoff wheel. The hard part was that the TPS plug is turned 90 degrees from the stock location towards the back of the engine. With the bell housing there, it gets a little tight to plug the loom in. So careful measurement had to be made to make sure everything would fit.
What I came up with was a two piece design that consisted of a machined block that mates to the TPS, and a sheet metal 't' that flips it 90 degrees and mounts the assembly to the stock TB.

Attached Image
TPS brackets. You can see that the sheet metal part was all done by hand. It's functional.
Attached Image
Assembled TPS mount alongside new TPS. You SDS guys will be familiar with that part.
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Installed.
Mark D.
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Posts in this topic
BMXerror   All the cool kids are doing it...   Sep 17 2007, 09:42 PM
BMXerror   Then Nowish Progress pics will be uploaded soon,...   Sep 17 2007, 09:45 PM
SGB   Number 419. Ha. Or rather, Ah.   Sep 17 2007, 09:56 PM
BMXerror   Yeah... And I had NARVW on the rear trunk. Mark D.   Sep 18 2007, 12:25 PM
BMXerror   Well, let's start with the first custom fabbed...   Sep 18 2007, 12:31 PM
BMXerror   The main bar is 1 1/8" DOM steel. The ends a...   Sep 18 2007, 12:36 PM
BMXerror   A couple months ago, I had an electrical short und...   Sep 18 2007, 01:03 PM
BMXerror   Center-punch marks for the future gauge centers. T...   Sep 18 2007, 01:07 PM
BMXerror   If you look closely, you can see some of the old f...   Sep 18 2007, 01:13 PM
sww914   If you plan to race, read the rules of the club(s)...   Sep 18 2007, 01:49 PM
BMXerror   Agreed. I am familiar with the SCCA rules for GT a...   Sep 18 2007, 02:13 PM
BMXerror   The next item is harnesses. This is the project th...   Sep 19 2007, 12:58 PM
BMXerror   These little plates were fun to make. I made the d...   Sep 19 2007, 01:08 PM
BMXerror   While trying to figure out how far down to paint, ...   Sep 20 2007, 11:34 AM
BMXerror   More... Mark D.   Sep 20 2007, 11:39 AM
BMXerror   After I stripped the rubber crap off. I then cle...   Sep 20 2007, 11:41 AM
BMXerror   I decided to double it up by fabbing some new floo...   Sep 20 2007, 11:49 AM
Bartlett 914   You have done a lot of nice work! I know you w...   Sep 20 2007, 03:17 PM
BMXerror   Yeah, I'm aware of those. They look really coo...   Sep 20 2007, 04:15 PM
Aaron Cox   i hope your seats have a belt hole in them. or yo...   Sep 20 2007, 05:46 PM
BMXerror   The SCCA GCR calls out 20 degrees, which is approx...   Sep 20 2007, 07:38 PM
Aaron Cox   The SCCA GCR calls out 20 degrees, which is appro...   Sep 20 2007, 08:45 PM
BMXerror   Nevermind   Sep 21 2007, 12:45 PM
Blood red 914-6gt   Anymore pics of your work?   Sep 21 2007, 05:44 PM
BMXerror   Okay, I haven't posted on this thread in quite...   Dec 5 2007, 01:10 PM
BMXerror   Now to actually mounting the harnesses. I made som...   Dec 5 2007, 01:17 PM
BMXerror   The lap belts were done much the same as the anti-...   Dec 5 2007, 01:22 PM
BMXerror   After that, I was ready to paint. These next few p...   Dec 5 2007, 01:28 PM
BMXerror   Close ups. Mark D.   Dec 5 2007, 01:30 PM
BMXerror   Grade 10.9 M12 X 1.5 bolts threaded into Grade 12....   Dec 5 2007, 01:39 PM
Blood red 914-6gt   Your work is looking good. Keep it up, and keep po...   Dec 5 2007, 01:43 PM
BMXerror   Your work is looking good. Keep it up, and keep p...   Dec 6 2007, 09:32 PM
BMXerror   With the seats in: I actually run without a seat ...   Dec 5 2007, 01:46 PM
BMXerror   I've also been working on getting some gauges ...   Dec 5 2007, 02:06 PM
BMXerror   ... and up to the top side of the engine bay. Ma...   Dec 5 2007, 02:09 PM
BMXerror   The last little section back to the CHT sensor (on...   Dec 5 2007, 02:13 PM
BMXerror   Now for the scary part; cutting giant holes in my ...   Dec 5 2007, 02:23 PM
BMXerror   I don't yet have the Oil Temp sensor in, but t...   Dec 5 2007, 02:41 PM
BMXerror   Oil pressure sensor mounted VIA adel clamp on the ...   Dec 5 2007, 02:48 PM
McMark   Looks great. I love these threads. :D Doin...   Dec 6 2007, 09:38 PM
BMXerror   Looks great. I love these threads. :D Doin...   Dec 7 2007, 11:55 AM
sww914   I ran my car with a stock 914 seat with no cushion...   Dec 7 2007, 12:19 AM
J P Stein   Depending on who/what/where group you're going...   Dec 7 2007, 06:57 AM
okieflyr   JP, What if he were to weld up some "hoops...   Dec 7 2007, 08:45 PM
J P Stein   JP, What if he were to weld up some "hoops...   Dec 8 2007, 09:35 AM
John   [quote name='okieflyr' post='974823' date='Dec 7 ...   Dec 8 2007, 08:50 PM
ChrisNPDrider   The stock seat w/o cushion works great. I have a n...   Dec 7 2007, 08:26 PM
BMXerror   Yeah, I was supposed to get some sport seats(with ...   Dec 8 2007, 07:13 PM
theo   yeah i have got a kirkey seat i love it, it'l ...   Dec 8 2007, 07:31 PM
BMXerror   Updates: They are many actually. I'm pushing p...   Apr 15 2008, 11:58 PM
flesburg   John and I share a DE car. We read and reread the...   Apr 22 2008, 08:48 PM
BMXerror   Yeah. I'll have to check with the organizers o...   Apr 24 2008, 12:21 AM
rufio0205   do the seat bolts that you put in stick thru both ...   Apr 24 2008, 07:56 AM
BMXerror   Well, I haven't posted anything in a while bec...   Jul 11 2008, 10:16 PM
BMXerror   I did a full inspection of the case and it actuall...   Jul 11 2008, 10:20 PM
BMXerror   More. With EFI and ignition on the stand. Mark ...   Jul 11 2008, 10:21 PM
BMXerror   Oops... Forgot these! After pocketing out the ...   Jul 11 2008, 10:24 PM
BMXerror   AA Products piston and cylinder kit. Note the or...   Jul 11 2008, 10:28 PM
BMXerror   Technical difficulties!   Jul 11 2008, 10:32 PM
BMXerror   I had to install an AFR gauge to monitor the fuel ...   Jul 11 2008, 10:32 PM
BMXerror   >:(   Jul 11 2008, 10:32 PM
Eric_Ciampa   Problems??? BTW, if you are looking for a cheap r...   Jul 11 2008, 10:51 PM
BMXerror   Problems??? BTW, if you are looking for a cheap ...   Jul 11 2008, 11:39 PM
BMXerror   Here's a couple bad pics taken from under the ...   Jul 11 2008, 11:29 PM
Eric_Ciampa   I thought you were having some kind of mechanical ...   Jul 12 2008, 12:00 AM
BMXerror   I thought you were having some kind of mechanical...   Jul 12 2008, 10:39 AM
BMXerror   Forgot this one. This is the rats nest that's ...   Jul 12 2008, 05:43 PM
BMXerror   Latest addition. This is the Sparco seat that Eric...   Jul 22 2008, 09:27 PM
BMXerror   This is after a layer of paint. Oh, and nobody nee...   Jul 22 2008, 09:37 PM
Phoenix 914-6GT   Nice :D I have the Evo2. Similar seat. I love it. ...   Jul 23 2008, 02:33 AM
BMXerror   Well, after the side track with the engine I got b...   Aug 22 2008, 04:44 PM
BMXerror   For drop links I simply purchased the Weltmeister ...   Aug 22 2008, 04:46 PM
BMXerror   I got the bearings from the Big Bearing Store onli...   Aug 22 2008, 04:59 PM
BMXerror   Right now the adjustment is pretty well on the loo...   Aug 22 2008, 05:08 PM
BMXerror   So, I got basically all that Tarret and Weltmeiste...   Aug 22 2008, 05:19 PM
BMXerror   Well, this is the first work I've done since A...   Oct 26 2008, 05:09 PM
carr914   Mark, good to see you back working on the car. You...   Oct 27 2008, 06:46 AM
BMXerror   So this is what I was up to this week. See, last w...   Jan 3 2009, 09:21 PM
BMXerror   This is the dash before startup. All switches down...   Jan 3 2009, 09:48 PM
Phoenix 914-6GT   Nice work. Keep us posted how everything works :be...   Jan 3 2009, 10:25 PM
BMXerror   Well, no pictures on this post because it's no...   Mar 29 2009, 10:28 PM
BMXerror   Well, since the rear suspension is well sorted now...   Oct 17 2009, 06:21 PM
BMXerror   First retainer. Second retainer. Mark D.   Oct 17 2009, 06:23 PM
BMXerror   This was my original plan for hardware. I only end...   Oct 17 2009, 06:26 PM
BMXerror   *If you don't want to read my lame story, skip...   Jan 26 2011, 11:07 PM
BMXerror   One more. Just enough clearance between that scr...   Jan 26 2011, 11:08 PM
BMXerror   Since I'm going to crank fired ignition, anoth...   Jan 26 2011, 11:15 PM
BMXerror   Originally, when I decided that I wanted to go to ...   Jan 26 2011, 11:28 PM
BMXerror   Sleeves. The small end was held to +/-.0001" ...   Jan 26 2011, 11:34 PM
BMXerror   Injectors installed. Feels good to start putting ...   Jan 26 2011, 11:39 PM
yeahmag   Mark, I'd love to see a parts list for your m...   Jan 27 2011, 12:40 AM
BMXerror   I'm actually supposed to be running with SCCA ...   Jan 27 2011, 01:39 PM
yeahmag   I ran, not walked away from SCCA. I got tired of t...   Jan 27 2011, 05:05 PM
J P Stein   I ran, not walked away from SCCA. I got tired of ...   Jan 27 2011, 06:47 PM
yeahmag   Depends on what class you are in, but for a 914 - ...   Jan 27 2011, 06:49 PM
BMXerror   Quick update here. I'm not sure if I mentioned...   Feb 6 2011, 11:54 AM
BMXerror   A couple more things that I did a while ago. When ...   Feb 6 2011, 02:00 PM
BMXerror   The cables were just purchased from O'Reilly. ...   Feb 6 2011, 02:08 PM
BMXerror   Wiring in the inner fender to the battery switch...   Feb 6 2011, 02:19 PM
messix   your master off switch needs to cut all the power ...   Feb 6 2011, 04:04 PM
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