FYI: Official Alien Build thread Started 2003, Alien Resurection is underway. Flywheel changed direction - transaxle is altered - Starter still works Options

[rick 918-S]

Some of the challenges as I move forward with this modification are the hydraulic clutch and the axles. The 5 speed as stated is off set. As a general explanation with out real measurements, the inboard flanges are about 1" different from side to side.

The right side may accept a lomger 914 axle length. I bought a couple used 944 axles for the CV joints. I plan on running a 944 CV on the inboard side and a 914 CV on the out board side for this year. I have drilled 914 stub axles. I have run 914 CV's at an extended angle in this car for 22 years. I only had one fail when I dropped the clutch in first gear showing off. (IMG:style_emoticons/default/slap.gif) After an examination I discovered it had extensive wear.

Thanks to Eric Shea's suspension thread and the research he did, I believe at this point the left side will accept a 911 axle. I purchased one off ebay to try. It should arrive in the next week.

The axles actually align better than when I had the 901 installed. They will run straight across. If the 69-75.5 911 axle works on the left side I plan to have an spacer machined to attach to the right side inboard flange to set this up with equal length axles.

I purchased a set of Boxster cables off ebay as well. I laid them out under the car and they appear to be a length I can use as is. I still need a shifter but I have plenty to finish up before I get that far. Stay tuned!

The mount extension bolted to the car is 3/16 wall 1 X 2. The thru holes are sleeved with welded in tubing to prevent crush from the bolts. I need to replace the extension to mount bolts. I have 16mm X 40mm long bolts. I need to move up the 45mm length to engage the locking nut.

(IMG:style_emoticons/default/assimilate.gif)

[Root_Werks]

Dang, seeing the power train back in the Alien is pretty sweet! I know still a ways to go, but that's progress!

[ClayPerrine]

Some of the challenges as I move forward with this modification are the hydraulic clutch and the axles. The 5 speed as stated is off set. As a general explanation with out real measurements, the inboard flanges are about 1" different from side to side.

The right side may accept a lomger 914 axle length. I bought a couple used 944 axles for the CV joints. I plan on running a 944 CV on the inboard side and a 914 CV on the out board side for this year. I have drilled 914 stub axles. I have run 914 CV's at an extended angle in this car for 22 years. I only had one fail when I dropped the clutch in first gear showing off. (IMG:style_emoticons/default/slap.gif) After an examination I discovered it had extensive wear.

Thanks to Eric Shea's suspension thread and the research he did, I believe at this point the left side will accept a 911 axle. I purchased one off ebay to try. It should arrive in the next week.

The axles actually align better than when I had the 901 installed. They will run straight across. If the 69-75.5 911 axle works on the left side I plan to have an spacer machined to attach to the right side inboard flange to set this up with equal length axles.

I purchased a set of Boxster cables off ebay as well. I laid them out under the car and they appear to be a length I can use as is. I still need a shifter but I have plenty to finish up before I get that far. Stay tuned!

The mount extension bolted to the car is 3/16 wall 1 X 2. The thru holes are sleeved with welded in tubing to prevent crush from the bolts. I need to replace the extension to mount bolts. I have 16mm X 40mm long bolts. I need to move up the 45mm length to engage the locking nut.

(IMG:style_emoticons/default/assimilate.gif)

Cantilevered mounts are somewhat problematic. This will put bending stress on the bar under load. With the HP and torque of the engine you have, it may cause a future failure due to metal fatigue.

I would suggest that you make the rear mount angle forward to bolt into the center of the bar where the R is written. Then add another mount that attaches with the same bolts as the shift cable mount, and the other end attaches at the same place as the rear mount. This will eliminate all the bending stress and potential metal fatigue.

Just my $.02.

[rick 918-S]

Some of the challenges as I move forward with this modification are the hydraulic clutch and the axles. The 5 speed as stated is off set. As a general explanation with out real measurements, the inboard flanges are about 1" different from side to side.

The right side may accept a lomger 914 axle length. I bought a couple used 944 axles for the CV joints. I plan on running a 944 CV on the inboard side and a 914 CV on the out board side for this year. I have drilled 914 stub axles. I have run 914 CV's at an extended angle in this car for 22 years. I only had one fail when I dropped the clutch in first gear showing off. (IMG:style_emoticons/default/slap.gif) After an examination I discovered it had extensive wear.

Thanks to Eric Shea's suspension thread and the research he did, I believe at this point the left side will accept a 911 axle. I purchased one off ebay to try. It should arrive in the next week.

The axles actually align better than when I had the 901 installed. They will run straight across. If the 69-75.5 911 axle works on the left side I plan to have an spacer machined to attach to the right side inboard flange to set this up with equal length axles.

I purchased a set of Boxster cables off ebay as well. I laid them out under the car and they appear to be a length I can use as is. I still need a shifter but I have plenty to finish up before I get that far. Stay tuned!

The mount extension bolted to the car is 3/16 wall 1 X 2. The thru holes are sleeved with welded in tubing to prevent crush from the bolts. I need to replace the extension to mount bolts. I have 16mm X 40mm long bolts. I need to move up the 45mm length to engage the locking nut.

(IMG:style_emoticons/default/assimilate.gif)

Cantilevered mounts are somewhat problematic. This will put bending stress on the bar under load. With the HP and torque of the engine you have, it may cause a future failure due to metal fatigue.

I would suggest that you make the rear mount angle forward to bolt into the center of the bar where the R is written. Then add another mount that attaches with the same bolts as the shift cable mount, and the other end attaches at the same place as the rear mount. This will eliminate all the bending stress and potential metal fatigue.

Just my $.02.

It will be fine. It is mounted the same way Porsche did it in the Boxster only with a wider span at the mounting points similar to the 901.

[tygaboy]

On the mount, it's the "big ones" on the side that matter. In the Boxster, that rear mount was only used for the muffler (at least on the G86-20 box) so I don't think I'd worry about that at all. Unless I'm missing something which is entirely possible...

[rick 918-S]

On the mount, it's the "big ones" on the side that matter. In the Boxster, that rear mount was only used for the muffler (at least on the G86-20 box) so I don't think I'd worry about that at all. Unless I'm missing something which is entirely possible...

My transaxle is different than yours. There was a mount on the back on my transaxle Maybe for the muffler. I did a search and see there was some puny thin sides mounts possibly bolted to the case. That would be fine for 200 hp and 181 lbs of torque. (IMG:style_emoticons/default/yawn.gif) If I break this transaxle the way I have it bolted up I would be shocked. We shall see. (IMG:style_emoticons/default/assimilate.gif)

[rick 918-S]

Checking CV freeplay. This is a 944 CV on a 914-4 axle

[rick 918-S]

Bought a shifter sight un seen. It's missing all the hardware. The good news is the Boxster cables are the right length for the 914.

[rick 918-S]

I had another small snag. As stated the left side axle ended up shorter than the right. The 914-4 axle length is fine on the right. I purchased a 911 axle for the left side. But unfortunately I would need to do a considerable upgrade to the stub axles an brakes I am not ready to do this year. I stumbled on to an axle the same length as the 911 from a VW Bus. So that is my next attempt to get this car back on the road this year.

[East coaster]

The shaft is short or you need one shorter?

[worn]

The more I studied the flywheel the more I disliked it. I weighed it and it weighed more the the stock steel monstrosity that Porsche hung off the end of the crank. I ditched one of the 1" aluminum discs I made and the 1//4" plate I was using as an intermediate plate to run all my fasteners through. I ended up dropping 10 lbs off the weight of the assembly.

This brought on a whole new problem. The bellhousing was now 1 1/4" too long. So as I did with the original 901 conversion, I got out the router with a slot cutter and shortened it.... (IMG:style_emoticons/default/idea.gif) (IMG:style_emoticons/default/blink.gif) (IMG:style_emoticons/default/screwy.gif) (IMG:style_emoticons/default/assimilate.gif)

Weapon of choice:


Before the surgery:


After the surgery:


Removed:

You did what??!!

[rick 918-S]

The more I studied the flywheel the more I disliked it. I weighed it and it weighed more the the stock steel monstrosity that Porsche hung off the end of the crank. I ditched one of the 1" aluminum discs I made and the 1//4" plate I was using as an intermediate plate to run all my fasteners through. I ended up dropping 10 lbs off the weight of the assembly.

This brought on a whole new problem. The bellhousing was now 1 1/4" too long. So as I did with the original 901 conversion, I got out the router with a slot cutter and shortened it.... (IMG:style_emoticons/default/idea.gif) (IMG:style_emoticons/default/blink.gif) (IMG:style_emoticons/default/screwy.gif) (IMG:style_emoticons/default/assimilate.gif)

Weapon of choice:


Before the surgery:


After the surgery:


Removed:

You did what??!!

LOL! You need come.over and catch up
(IMG:style_emoticons/default/beerchug.gif)

[rick 918-S]

The shaft is short or you need one shorter?

Left side is 914 length. Approximately 20 1/4" The left side is a Bus axle Approximately 18 3/4. I have to have the 914 axle cut to accept 944 CV'S on the inboard side and the Bus axle CV is also wider. The Bus axle mates to my outboard side. I have them on order waiting for them to arrive. Supposed to be tomorrow.

[rick 918-S]

BTW: I roughed in clutch plumbing and with Sandy's help we got it bled. You can't know what a relief it was to see the clutch actually released!

After building a custom flywheel, cutting the transaxle off, my math seemed to work out in the end.

944 Master Cylinder, Audi 90 Quattro/Porsche Boxster threaded Slave 1/4" line with modified 12mm fittings.

Just about time to blow this thing apart and start to clean it up for reassembling.

[rick 918-S]

CV research is exhausting. The Bus axle has 100mm CV's so no go on the outboard side. I bought a Beetle axle thinking that would get me rolling. Turns out VW Beetle CV's are course spline. Searched for 912 CV's. You can purchase a whole axle with new boots and bolts (2 CV's which is what I need) for around $50.00 bucks. But I am suspicious they are reconditioned Beetle axles with course spline. The photos of the parts show a narrow taper on the stub axle side like the Beetle. (IMG:style_emoticons/default/idea.gif) (IMG:style_emoticons/default/dry.gif)

Ya ya, I know I can spend my retirement money on 911 conversion. You have to realize I have abused 914-4 CV joints since the car was first completed in 2004. In all those years I only had one fail. After pulling it out I discovered the reason it failed was because it was completely worn out.

[Luke M]

Hi Rick, So what is it that you need? Modified 914 axles to mate 100 mm fine spline cv to? What do you have for outer hub/stubs?

I have a set of modified 914 axles that will take the 100 mm fine spline cv. I'd have to dig out my axles to find that part #s on the cv box.

[rick 918-S]

Hi Rick, So what is it that you need? Modified 914 axles to mate 100 mm fine spline cv to? What do you have for outer hub/stubs?

I have a set of modified 914 axles that will take the 100 mm fine spline cv. I'd have to dig out my axles to find that part #s on the cv box.

Thanks Luke. I am just whining. Here's what I have. Right side 914-4 axle
I had the inboard side cut to accept a 944 100mm CV. The 944 is a 27mm spline size with a 33 tooth spline count. I am staying with 914-4 outboard CV's for now. Eric has them on his site. I am a typical cheap SOB hence the whining.

I have a VW Bus axle on the left. It takes 100mm CV joints 27mm spline end with a 33 spline count. So the inboard side is a bolt on with no drama.

What I did to get the 100mm 944 CV's was purchase a new 944 axle. I think I paid $ 45.00 shipped. That is 2 CV joints with boots and bolts. I think I exhausted my CASOB options. (IMG:style_emoticons/default/dry.gif)

[Luke M]

Hi Rick, So what is it that you need? Modified 914 axles to mate 100 mm fine spline cv to? What do you have for outer hub/stubs?

I have a set of modified 914 axles that will take the 100 mm fine spline cv. I'd have to dig out my axles to find that part #s on the cv box.

Thanks Luke. I am just whining. Here's what I have. Right side 914-4 axle
I had the inboard side cut to accept a 944 100mm CV. The 944 is a 27mm spline size with a 33 tooth spline count. I am staying with 914-4 outboard CV's for now. Eric has them on his site. I am a typical cheap SOB hence the whining.

I have a VW Bus axle on the left. It takes 100mm CV joints 27mm spline end with a 33 spline count. So the inboard side is a bolt on with no drama.

What I did to get the 100mm 944 CV's was purchase a new 944 axle. I think I paid $ 45.00 shipped. That is 2 CV joints with boots and bolts. I think I exhausted my CASOB options. (IMG:style_emoticons/default/dry.gif)

Gotcha.. I thought you where in need of some modified axles to make things work.
I have documentation that's needed for that portion but sounds like you're all set with that. I have the 100 mm cv and floating axle setup for my 6 with a 915 trans.

[rick 918-S]

CV's are on the way from PMB.

I have a working hydraulic clutch.

Received my GPS Speedo from Speed Hut.



Time to blow this thing apart and start the clean-up from several years of just driving it and sticking it away until the next time.

[rick 918-S]

You dry state guys have no idea how good you have it. After another round of removing dirt soaked oil it's on to the prep work to repaint the bottom of the car. I think I first did this around 1995...

The Alien lives on.