Sixer Project Mechanically Completed and Road Testing Options

[shoguneagle]

The mechanical aspects of my Sixer Project are coming to a close with just one modification left to (911 e-brake cables). Just to get to this point, seven years and considerable changes have taken place to the car which still needs to be sanded, sealed and painted.

I really enjoyed building this car much more than the 914-V8 I built back in the late seventies. This car handles so much better and is better balanced. It will be a joy to take long distance trips in it once I get the dependability established.

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Always wanted to add the above quote and decided to do it before anyone else. (IMG:style_emoticons/default/driving.gif) (IMG:style_emoticons/default/driving.gif) (IMG:style_emoticons/default/driving.gif) (IMG:style_emoticons/default/driving.gif) (IMG:style_emoticons/default/driving.gif) (IMG:style_emoticons/default/driving.gif) (IMG:style_emoticons/default/driving.gif) (IMG:style_emoticons/default/driving.gif)

The pictures will be coming shortly showing the current status of the car and a report on how it is doing.

The car is 1974 914 converted to 1987 911 Carrera Sixer engine. It has retained all the original engine injection and related components except I installed a K&N inlet system. I am using the stock 1987 911 oil tank with all the 911 guages working and installed. I added a vacuum guage and amp guage. In addition, the oil system has a thermo/bypass valve and front oil cooler installed.

Exhaust consists of the original 1987 heat exchangers and heating system connected and working. Everything does fit and does work.

The exhaust system consists of two exhaust pipes with two CAT converters attached to each. I am making water at each tailpipe. A little noisy at high rpm's but below 3500 it is ok.

I had the Great Doc Evil work is majic on the transmission and it came back with the 3rd, 4th, and 5th gears changed to match the 3.2 engine. He did a great job; excellent asset for our cars.

Front suspension consists of a completely rebuilt rack and pinion, new 21mm torsion bars, 22mm sway bars, Koni Reds Adjustable shocks, Elephant Racing brass inserts on the torsion bar housings with zert fittings, etc.

Rear suspension consists of rear trailing arms having new Elephant Racing brass inserts on the suspension with zert fittings, Elephant Racing Bolt kit and inserts, 180-200lbs springs with adjustable perches, Koni Reds Adjustable shocks, stock rear sway bar with new attachment inserts, etc.

Front and rear brakes are complete 911 Carrera type including e-brake. Eric provided me with great insight and information regarding this matter which made the conversion easy. I am running the 911 rotors, calipers, etc which came from a 1987 Carrera.

Rear half-shafts (sway-a-way), 108mm CV Joints, 911 hubs, transaxle drive flanges, etc. have been changed over to handle the 3.2 engine power.

Several stress kits have been added from our vendors such as Racer Chris and many others. This project could not have been completed without their input of information and quality products. The rear suspension is stressed where the rear suspension attaches, longs with Brad Mayuer's kit, Engleman's inner kit, etc. The body has been seam welded in critical parts, etc. In short, the body does not flex which could be good or bad depending on application - actually a little stiff for road car, could be best for the race track; have to see about adjusting the suspension to the best possible use. There are probably many other things done but this info at least gives the background what has been done to the car.

I have used one of our vendor's fuse box and changed everything over to the blade type fuses. I have installed fuses on wires running from the battery to the different battery hot wires for protection while starting and troubleshooting. These I will leave since I think they give a protection to the electric system.

I stll need to prepare the body for paint, sand and seal, paint. This will follow next year and should be ready for the events in the Bay Area in 2014.

Additional items to add include the seals, interior (which has already been done), cover the dash front and top, emergency brake cables, etc.

Car has fiberglass fender extensions which encase 17inch Cup II rims running:
front - 7 inch 205/50 with spacers; rear - 9inch 235/45 with spacers.

I do not know nor do I care how much money was spent since this has been a very enjoyable seven year project and I have met great people. It is well worth the entire effort. Any additions to this project may be a hitch assembly and building a 914 trailer. This sounds interesting and could be used in traveling/camping, etc. Only time and future will determine any additional continuation to this project after painting/driving/adjustments/etc.

Shake down trils beging this coming Saturday between rain storms. (IMG:style_emoticons/default/driving.gif) (IMG:style_emoticons/default/driving.gif) (IMG:style_emoticons/default/beer.gif) (IMG:style_emoticons/default/beer.gif) (IMG:style_emoticons/default/beerchug.gif) (IMG:style_emoticons/default/beerchug.gif) (IMG:style_emoticons/default/beer3.gif) (IMG:style_emoticons/default/beer3.gif) (IMG:style_emoticons/default/beer3.gif) (IMG:style_emoticons/default/beer3.gif) (IMG:style_emoticons/default/beer3.gif)

[billh1963]

Great write-up....looking forward to the pictures!

[Cairo94507]

Sounds very nice; looking forward to the pictures too.

[shoguneagle]

Do not know how nice it is or looks since I have clean up several items.

I got the exhaust installed and drove it home in second gear. As soon as I moved into traffic I felt the shift rod at the gear shift lever slip in the middle of traffic. Managed to lock the trans into second gear and drove home through five stop lights. Engine, clutch, and brakes working perfectly. Only thing bad is the shift lever. Should have it fixed this week end.

I really did a "dumb thing" and left the oil tank cap off after checking the tank level when car was warmed up. Went out a while later and found 3-4 quarts on the garage floor.. Should know better. Car is now running with the problems mentioned above and some driving adjustments which have to be made.

I am very happy about the car. Just cleanup and prepartion/painting.

Pictures should be attached shortly.

Steve

[rktmn247]

Glad your conversion is running! Sounds like you are down to the short strokes. I would really like to see pics of your exhaust system from underneath. I'm very curious.
Also, where did your mount the stock 911 oil tank? Thanks for posting your progress!

[shoguneagle]

The areas that I need to clean up involve the heating area and the rear oil tank installation. Some people may not like the installations but I had rust in the areas so modification was in order. Remember, my car was a roller which has been returned to the street - a total rework project.

The pictures are being prepared and focused on the car at this stage of the game and will be posted to this thread. Should have them shortly.

The oil tank is mounted laterally across the rear of the car in the trunk. I had rust in this area and wanted to match the oil capacity of the stock 911 configuration to the engine requirements. This area is subject to rearend accidents but the car is only going to be driven on special events activities. Oil lines are routed up the center of the engine/transmission, etc.; and, it does have a front oil cooler.

I had headers installed without any heat/defroster capability. I do not mind the cold weather, but I will not drive without defroster. I really hate the fogging of windshield.

Steve

[ThinAir]

Looking forward to seeing it!

I saw a multi-colored flaired 914 on a flat-bed tow yesterday on Hwy 180 and wondered if it was yours.

[shoguneagle]

Yes. That was the car going to the muffler shop. Got it back and had some transmission and oil leak problems. Getting them straightened out now.

Steve

[JmuRiz]

Can't wait to see some pictures, I like the out of the box thinking described.

[shoguneagle]

I have not forgotten my promise for pictures. Still tied up with transmission shifting problems. Should be here shortly irregardless of my transmission problems.

Steve

[shoguneagle]

This photo reflects the new locations for the 911 Carrera oil tank, breather hoses, battery, etc.

[shoguneagle]

Another view of the rear trunk showing the oil tank, breather lines, battery and heater hoses going to the heat exchangers.

[shoguneagle]

The 911 instruments etal

[shoguneagle]

Another of the progress completed

[shoguneagle]

Left side underneath showing the bottom heater exchange and related hoses. Also shows the axle mods done converting everything to 108mm CV Joints, etc. Again the exhaust system left side

[shoguneagle]

oil lines routed underneath the car

[shoguneagle]

right side of transaxle showing clutch cable attachment and routing. Note the clearance around the installed stock heat exchangers/exhaust from the 911 Carrera

[shoguneagle]

shows some of the throttle at the right side of the transmission

[shoguneagle]

[shoguneagle]