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76-914
All the hoses are tied in and it got a little crowded. The red circles are ends of the same hose that loops up/down to make connection. Same with the blue except it loops down/up. Look at the 3rd circle in the shadow and you see it. The urethane foot rest will be channeled to bed the hoses flush, I hope. biggrin.gif

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After the AC is working I need to wrap some more of that sticky black rubber around the exposed metal of the pressure (small) line.

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And the two heater lines on top of the AC ports.

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Freon later this week. I test the heater and defrosters tomorrow. beerchug.gif Kent
76-914
I was able to button it up this week; several times. mad.gif Sorting out gremlins and making things fit. smash.gif sawzall-smiley.gif The defroster actually blows. I thought it was pretty good then noticed it was on low. Yeah, it works. I did manage to sheeplove.gif a few hours away chasing what I presumed was a vacuum leak only to discover that I needed to turn the blower on before it would energize the vacuum solenoid to the heater valve. headbang.gif I found that I have the lines to the heater crossed at the by pass valve but it will just have to stay that way until after the G&R meet manana. evilgrin.gif

Here's a pic of the footrest after a little grooving for the hose. Since I completed the freon connections at the condenser I was able to finally run the condensate drain. Previously I wasn't sure what would end up where and yadi, yadi. It exits almost in the corner. Off 'bout 1".

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Here is why. I wanted to place it exactly in the corner but found the jack point piece would be compromised. To miss drilling thru the meat of that piece meant moving appx 1.5" further away from the corner or................drilling the hole dead center of the cone. The piece will push up when the jack point is used too.

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Trimmed the speaker pod to fit. It wasn't primo before and it damn sure ain't now but it tidies the area up once in place.

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I punched a hole in my new carpet (thx Mikey) for the condensate drain. sad.gif Sacrifices were inevitable.

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Just a few pics of the inside after everything was back together. This coming week I should be able to charge and freeze. I hope, I hope, I hope. So many things to go wrong. wacko.gif I can see the light at the end of the tunnel getting brighter. beerchug.gif

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The left panel ended up getting a trim where the new duct crosses over.


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76-914
I hit a little hitch with my AC so I decided to jump into installing my new dash. It took a bit of "self persuasion" before I could begin to remove everything I had installed in the previous week but "asi es la vida". I used the thread in the Lapuwali Forum and found it quite useful, however I believe that the removal of the glove box and the related "dreaded door spring" wasn't necessary and will confirm once the new dash top is installed tomorrow. The only nut that was difficult was the one on the far right side facing the front. It can be removed with a 13mm crows foot or heat up and bend a cheap HF wrench to fit. I'll shoot a pic of this for the re-installation.

Out with the old


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As I was fidgeting with the installation one of the plastic studs pop out. Got me to cussing a bit but in hind site I'm glad it happened. It was easy enough to thread the stud back into the metal threaded piece inside the dash. I decided to check how well the plastic nut would thread on incase I had boogered the threads. blink.gif I couldn't get ANY of the plastic studs to accept the OEM plastic nuts. confused24.gif OK. I then tried a 13mm metal nut. Same thing. WTF.gif Since I have the patience of a charging Rhinoceros I decided to try this instead. I used a piece of threaded rod I had setting around and cut 9- 7/8" long pieces then set them 5/16" deep into a bit of silicone to lock. Don't set them any deeper than 5/16". This leaves 9/16" exposed. Same as the OEM. Don't throw away the old plastic studs. You might need one like I did. On mine, the far left stud would not thread in. I found the metal threaded piece was "hammered" confused24.gif . I felt the metal tab might dislodge if I tried to tap it so I simply re-installed (read jammed) one plastic stud. Granted it was and is cross threaded into the dash but I don't see removing it in the near future. BTW, don't forget to run the plastic stud thru an 8mm die several times to resize to accept the plastic OEM nut.
I want to point out that the quality of this piece is very good and I expected some "teething issues" as mine is one of the first produced. Hope this helps some of you guys. beerchug.gif

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Chris H.
Nice work! beerchug.gif Dang your old dash was CRACKED!
euro911
Let me see if I've got this right - the new dash came with new studs? ... just the wrong size/pitch? confused24.gif
76-914
Yeah Chris, It looked like hammered dog stromberg.gif but thanks to Mark W. it will look a lot nicer now. The one in my white car is perfect; go figure. confused24.gif

Mark, they are pieces cut from an 8mm plastic thd rod, I believe. I say that because the length of each varies slightly. Most likely some Chinese product that got out of spec somewhere in production. I checked to see if they were 5/16" but they aren't. I did however use 5/16" because it "locked" into the shallow threaded receptacle a little tighter than 8mm did. ps, one can also use 5/16" brass closet bolts cut to length if you go 5/16". Brass is easier to cut!
euro911
... or just get some cheeeeep Chinese M8 nuts confused24.gif

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76-914
Hardly noteworthy but glad it is holding. As I mentioned earlier; I don't know stromberg.gif from Apple Butter about AC but I'm learning. I could pull it down but it would leak down almost immediately. I put some dye down the hose before tapping into the Freon can and there it was staring me in the face. The O-ring on the OEM fitting (circled in red) at the compressor was hard as a rock. Missed that slap.gif . The other leak was on the "New" crimp fitting (circled in red as well). Do you see the error? I didn't either until now. Look at the ferrule. Notice the indentations from the crimp aren't as pronounced as the fitting to the right of it? Yep, I crimped a #8 fitting with #10 dies. headbang.gif

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Mikey914
I tried to match the thread pitch with the OEM. We will now include matched nuts with these.
euro911
I had a feeling that waiting to ship would have some benefits happy11.gif
76-914
FWIW, Marks Dash Top appears to be an improvement over OEM as it is much more substantial. When each are held side by side, the OEM dash feels like a cheap imitation.

In other news: I finally got off my Ass and completed the VSS circuit. W/O that signal the ECU would completely cut out until I let off the throttle and pushed down on it again. It only happened if my throttle position remained steady for extended periods of time. It first raised it's ugly head on the trip to WCR2015. I almost stromberg.gif myself but soon realized how to manage it. It was never a problem in town as the peddle get moved a lot. Tom at the EZ30 board enlightened me so I tried it. In the process I discovered that I had connected the VSS signal wire to the ECU but failed to energize it. IOW's, I didn't connect the 12v or ground wire. I started it as I was rolling down the drive and the idle shot up. I stopped and said WTF.gif waited a few seconds and drove down the street in 2nd while it idled high. By the 3rd stop sign the computer accepted the new signal but something else cleared up which was a welcome bonus. Don't know why but the popping/backfire, which I had always attributed to an open and very short exhaust, went away. Sounds Bad Ass during down shifts now. I don't know if it cured the cut out on the hi way yet so I'll cross my fingers until I get it on the open road again. If that was it I see no reason not to install Cruise Control. evilgrin.gif Don't anybody tell Pat Garvey. stirthepot.gif
76-914
Damn, all this criticism of Marks product yet I forget to post some pic's of it installed. Those of you sitting on the fence should move on this. wub.gif Anyway, here it is installed. Onward thru the Fog!

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rnellums
Kent,

Just as a double check, that VSS signal is coming from the 3 pole sender on the passengers side of the transmission right? I want to make sure I've got it hooked up properly!

-Ross
76-914
Yep. GB to A1 and the other 2 are +/-. I couldn't find my wires listed, which are G, W & Br so I measured the dia of both and deduced the larger was +. Lucked out and got it right. Yours might be Gb=VS, Y=+ switched & B= -. How many miles you got on her, now Ross?
rnellums
Can't say for sure since I switched back to a stock-looking speedo(using the subie speed sensor) 3000 miles in, but probably close to 6k now. Only 22mpg on the last tank though, too many redline pulls for good fuel economy smile.gif! II got to drive rays conversion today, and I have to say, that hydraulic clutch is silky smooth. I'm going to be switching over this winter for sure.
euro911
QUOTE(76-914 @ Oct 18 2015, 04:05 PM) *
Damn, all this criticism of Marks product yet I forget to post some pic's of it installed. Those of you sitting on the fence should move on this. wub.gif Anyway, here it is installed. Onward thru the Fog!
Not criticizing Mark's products, just mentioned that my dash might be delivered with the 'patch' when it gets shipped shades.gif

I've spent thousands for a lot of awesome products that Mark makes available to us aktion035.gif ... I'm trying to get him to expand into the early 911/912 arena too idea.gif

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Chris H.
QUOTE(76-914 @ Oct 18 2015, 05:24 PM) *

FWIW, Marks Dash Top appears to be an improvement over OEM as it is much more substantial. When each are held side by side, the OEM dash feels like a cheap imitation.

In other news: I finally got off my Ass and completed the VSS circuit. W/O that signal the ECU would completely cut out until I let off the throttle and pushed down on it again. It only happened if my throttle position remained steady for extended periods of time. It first raised it's ugly head on the trip to WCR2015. I almost stromberg.gif myself but soon realized how to manage it. It was never a problem in town as the peddle get moved a lot. Tom at the EZ30 board enlightened me so I tried it. In the process I discovered that I had connected the VSS signal wire to the ECU but failed to energize it. IOW's, I didn't connect the 12v or ground wire. I started it as I was rolling down the drive and the idle shot up. I stopped and said WTF.gif waited a few seconds and drove down the street in 2nd while it idled high. By the 3rd stop sign the computer accepted the new signal but something else cleared up which was a welcome bonus. Don't know why but the popping/backfire, which I had always attributed to an open and very short exhaust, went away. Sounds Bad Ass during down shifts now. I don't know if it cured the cut out on the hi way yet so I'll cross my fingers until I get it on the open road again. If that was it I see no reason not to install Cruise Control. evilgrin.gif Don't anybody tell Pat Garvey. stirthepot.gif


I knew it! Getting this done in the next few days. I have some popping on decel which I also thought was my exhaust. That plus the other VSS symptoms...wth am I waiting for confused24.gif ?
76-914
Yep. You heard it here first. And just in time for Winter. Our coolest day in month's. Appropriate. dry.gif All joking aside, I couldn't believe it when I saw the gages come to life and the compressor kick in w/o being jumped. I'm happier than a two petered Billy Goat. I'm sure I will have teething pains to address but this entire process has been a mind bender for my little brain. I knew "0" about AC a few month's back and thx to the internet I now have AC/Heat/Defrost/heated seats. I may need to "open up" the front a bit or change radiators or increase fender ducting or...........who knows. I had the console in and out 6 times since I thought I was finished. mad.gif No matter. At this point the hard work is behind me and only a few mods in front of me. I suspect a few of those will come as next summers heat begins. Can't wait for Mark's roll bar trim to complete my interior. smile.gif
Chris H.
So working HEAT and AC? Dang. Might have to change the model number on that car. How's it working?
A&P Mech
Sir, you are my hero!
76-914
QUOTE(Chris H. @ Oct 20 2015, 10:12 AM) *

So working HEAT and AC? Dang. Might have to change the model number on that car. How's it working?

We'll see. av-943.gif Seriously, it's too early to say. Haven't driven around town with it yet. Also, I need a day at 90F + to dial it in. It was only 80F yesterday and my hi pressure side was at 190 which is just about right if you follow the std. formula of "ambient temp x 2 + 15% to 20%. IOW, don't want to Jinx myself by talking it up.

QUOTE(A&P Mech @ Oct 20 2015, 10:40 AM) *

Sir, you are my hero!

You need to be more selective in your choices. shades.gif You should do this. It can be done in a weekend for appx $1000 if your Andrew or 2 weekends for the average Joe. It's not that difficult if you have some direction. Mine took a long time because I had no idea of what, how and on n on. I ended up with plenty of legroom which surprised me. Onward thru the Fog. beerchug.gif
JRust
Well done my friend pray.gif . I have dreams of finishing mine. Right now I am wishing my heating unit didn't get taken apart. As a donor that we didn't use anyway. Would much rather have that in my car right now sad.gif . Still sweet to see yours up & running. Will make the long drives in heat so much nicer
76-914
I couldn't get a reply from any of our resident electrical specialist (in the "Electrical Question" thread) so I moved on without 'em. I may have stumped them idea.gif This is my situation. I wired my radiators to have a 2 speed function. Ground one of the 2 neg wires and it runs on low speed. If you ground both then it runs on high speed. On the other side is the ECU which normally controls the fan speeds. It also does this thru neg switching. There are 3 wires coming out of the ECU that "supposedly" control the fans. I was a little cautious in the beginning and twisted all 3 together hoping it worked. Well it has but now I want to see if I can determine which of these 3 switching wires does what and when? Make sense so far? I made a temp panel & mounted 3 LED lites in it and placed it so that I can see it in the rear view mirror when driving. My challenge was to isolate each lite from the circuit or all 3 would illuminate at the same time no matter which wire was active. IOW, they will all share a common (+) so if they also share a (-), which they do via the ground connection to the fans, they will all lite up. I placed a small switching diode on each of the 3 wires between the ECU & the junction of the 3 wires. Then I tapped into each wire with a (-) lead going to it's corresponding lite. Hopefully, I'll find that one is low, one is high and the 3rd is confused24.gif . Possibly on the AC circuit and controlled by AC pressures or just the activation of the AC compressor??? Who knows. My only concern in all of this is there can be issues when diodes are run in parallel. I'm hoping that I don't get any "bounce back" since I'm on the neg side. I won't know until I drive it a short little while. rolleyes.gif I did fuse the 12v+ connection to the LED's just in case.

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76-914
My new lift inspired me to replace my noisy and unacceptably low exhaust system. By using SS my product line triples and allows me to reconfigure the existing system thereby shortening it and allowing the use of a normal muffler. biggrin.gif

Here you can see it runs beneath the engine cradle giving it just 3" ground clearance! blink.gif

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An entire side with the whopping 10" Glass Pack. At the time, there wasn't room for anything else.

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This is the piece that should allow me to change things around and shorten it up. A 2" 2r 180' or U Bend.

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The 2" is too small so I will have to add a piece to fill the oval flange.

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This piece will need to have one end expanded at the muffler shop manana.

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I ended up with 1/2" clearance between the engine cradle and the drop arm when fully extended.

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Here's the end that will need cut, expanded and welded to complete the sharp turn 90'.

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If this works I'll order the pieces for the other side and the mufflers and flanges. Oh, almost forgot to say thanks to Mike (Mueller) for the SS wire. I owe you one. beerchug.gif
76-914
WCR convinced me that I did not have enough space when traveling with my wife. I bought the luggage rack from Steve a few months back. I still need to fab the proper brackets which are on the underside. Picked the lid up a couple of weeks ago from Ian, IIRC. The lid was from the 914 used in the "Wheeler Dealer" episode. Not that I give a Rat's Arse about that. The CF Wrap from Amazon for <$18. It's only use will be when we travel and I couldn't see dropping a bunch of $$ on this project or drilling holes in my existing lid.

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Chris H.
Like it! Did you get the exhaust finished?
76-914
QUOTE(Chris H. @ Dec 23 2015, 08:07 PM) *

Like it! Did you get the exhaust finished?

Waiting on the muffler. Once I have it in hand and if it works out I'll order the same stuff for the other side. I learned on the last system. If I order for both sides and I made a mistake then I've made it twice. sad.gif Plus, Summit has free shipping on orders over $99 so I'll keep the orders right above $99. First time around I ordered everything at once and ended up returning a few items and I ended up paying additional shipping charges because I didn't have enough for free shipping. Live and learn. Are you working on yours since Winter arrived??
Chris H.
Yeah it's been a mild winter. Been busy but hopefully soon. Getting some new tools for Christmas. Will be dropping the engine soon and fixing the leak at the oil pump. Also want to flip the manifold if I can. I found a stock intake on e-bay (finally!).
NeunEinVier
QUOTE(76%26%23045%3B914 @ Oct 16 2015, 05:35 PM) *

Mark, they are pieces cut from an 8mm plastic thd rod, I believe. I say that because the length of each varies slightly. Most likely some Chinese product that got out of spec somewhere in production. I checked to see if they were 5/16" but they aren't.


M8 threads come in 1.0mm and 1.25mm thread pitches, maybe they just happened to use the wrong pitch.
76-914
The muffler arrived yesterday and I was able to test fit it. The 4"x9" oval shape works. That's the good news. The bad is that I probably won't use this muffler. It's about as straight thru as the existing Glasspacks. mad.gif No problem. The shape was my main concern. My concerns were threefold. 1st was quite, then clearance and finally use the existing cutouts on the rear fairing.
If you think the U fitting weld joint isn't square your right. It was necessary to center up with the "channel" the muffler will sit in.

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These flanges will move in front of the stub axles for added clearance but they actually clear as they sit. I just don't see any sense in crowding the axles if I don't need to.

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The strap on the left side of the muffler will be R&R'd during assembly. Managed to hit the old cutout's in the rear fairing. biggrin.gif

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That 1/4" wood spacer between the muffler and rear sway bar is there until I spot weld the muffler up.

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You can see the ground clearance difference between the old system on the left and the new system on the right. piratenanner.gif Now that I know it will fit, it is ime to order the parts for the left side.

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rnellums
I went through all this too. The relatively large single exit limits your mandrel bend angle. I like how you ran the piepes under the axle. Did you run 2" all the way back?
76-914
QUOTE(rnellums @ Dec 25 2015, 11:50 AM) *

I went through all this too. The relatively large single exit limits your mandrel bend angle. I like how you ran the piepes under the axle. Did you run 2" all the way back?

Yeh Ross, it's 2" all the way. .5" clearance between axle and exhaust. I'll probably wrap the u joint and 90 to cut down on heat.
rnellums
I had mine internally and externally ceramic coated and it really seemed to help. The pipes hardly seem hot while running and cost <100$ for my entire system.
76-914
QUOTE(rnellums @ Dec 26 2015, 02:40 AM) *

I had mine internally and externally ceramic coated and it really seemed to help. The pipes hardly seem hot while running and cost <100$ for my entire system.

Was it Jet Hot Coating or do you have a link?
rnellums
I think the powder coater used Cerakote, I got the satin black coating as the aluminum engine has enough bling by itself!

76-914
I found this after a New Years Day run in the mountains. It also sheeplove.gif me at WCR and I thought the clamps would stop the rubbing but evidently not.

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Time to stop this stromberg.gif and bring everything inside. I did this on the other side originally. But I got cute with the drivers side and it didn't work so on to sawzall-smiley.gif

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Trim piece and a quick test fit. smash.gif

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Welded in and painted

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And Presto. I should have done this earlier but some times I convince myself that something is too much of a PITA and prolong the misery. shades.gif

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76-914
I forgot the member that originally posted on Dallas Coley's work but I sure want to thank him. "That" member, not to be confused with "That guy", recently posted he had Dallas refinish his license plate so I thought "What the Heck" and called Dallas. He said that he could indeed refinish license plate frames so I sent him this one....

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And $70 later (total incl shpg) I receive this, Dallas does good work and for those looking, I'd suggest you give Dallas a try. BTW, he has very good communication skills.

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76-914
It took about 5 min's to realize I hated my new mufflers. They were almost the opposite of the 4"x10" Glass Packs I had been running. The Glass Packs were loud as Hell when under load but had a sweet note at cruise. The 3 chambered MagnaFlows were quieter under load but louder at cruise + they produced a terrible drone. mad.gif So just for shits and grins I stuck the glass packs inline on the exhaust stub outs. I should have taken a pic. Looked like a Hill Billy mod. lol-2.gif But guess what? It now produced exactly the sound I was looking for but how to do this? idea.gif Bob (BIGKAT) had tried to tell me this a year ago but I didn't think there was room. Once again I was wrong as you can see in these 2 pic's. Just needed to use a couple of 90's, shorten my cable shift mount 1.5" and those glass packs fit right in.

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I had to weld in some stub outs after the 2 glass packs were stuck together.

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I added anther couple of flange sets so I could remove the new addition to service shifter attach points and cables.

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Added a little insulation for heat barrier.

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This is what I ended up with and the Dreaded Drone is gone. piratenanner.gif I'm running without a fairing for now but will probably add one later. confused24.gif

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rightpedal
I totally dig on the new exhaust. I'm a sucker for the center exit. Summit has a fully welded muffler that I run on everything. Its cheap, sounds good under power, and real quiet in cruse conditions.
They probably cost me a little power over a chambered muffler but I don't really care.

http://www.summitracing.com/search/product...-turbo-mufflers

Steve
rhodyguy
I wonder what that setup would sound like on a stockish t-4 running heat exchangers. Low cost alternative to the systems currently out there. Looks cool. Looking forward to the YouTube sound bite if you post one.
914forme
Thank you for the info Kent beer.gif , new setup looks good. So crap, Looks like I'll be running a rear Valance also. Mufflers hand down to far, time to dig mine up, and get to work, just when I thought that area was all done. headbang.gif

I am glad you found a solution to your issue, and where willing to share it once again.
thieuster
Any chance of a vid with sound? It looks very, very promising!

Menno
76-914
Thanks guys. I don't have a GoPro so I stuck my camera on the dash. Sound quality isn't great but it covers most driving styles and you'll get an idea. The top is off so there is wind noise. sad.gif https://www.youtube.com/watch?v=Jh-ClYj9LQ8...eature=youtu.be
euro911
Sounds good to me smile.gif
Chris H.
thumb3d.gif Nailed it. WAY quieter than before.
jimkelly
wow... sounds great!!
mgp4591
QUOTE(76-914 @ Jan 30 2016, 03:53 PM) *

Thanks guys. I don't have a GoPro so I stuck my camera on the dash. Sound quality isn't great but it covers most driving styles and you'll get an idea. The top is off so there is wind noise. sad.gif https://www.youtube.com/watch?v=Jh-ClYj9LQ8...eature=youtu.be

From what I can hear it sounds good but you're right, the quality isn't the best. Could you take a shot from the back with you starting up and give us a throttle goose or two?Maybe even hold a higher rpm for a bit at the speed it used to drone on you?
rhodyguy
You should have someone record a drive by @ around 5k rpm. No valance needed. You're a clever fellow. A bit of an extension on the outlets, just short of 'banging your shins', would look good too.
Mr.Nobody
Just read through the entire thread. Awesome info. Thanks for documenting everything.

Hope to see the car someday. I'm actually just south of you. I'm in SD, but my 914 is in Fallbrook.

Great job on your car beerchug.gif
76-914
Well thanks but you can ditch what I said about radiators and go this route if you do a conversion. The Sirocco radiator was fine unless you wanted to race uphill in 95F weather, add an AC or tax it in any way. IOW, it was minimal. Given others recent change over to the Celica GT version, I hopped aboard. It is a dual core unit that fits quite well in the space allotted. Price was $167 shipped to my front door. I'm a little skeptical of the fans that came with it but we shall see.
The first step was to build a frame to hold the new radiator and condenser. I won't bore you with the dimensions.

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You can see the rubber shocks in place that the radiator sits upon. These were pulled off the donor car 2 years ago, removed from the OEM bracket and added to this steel frame.

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Next the frame is welded at the bottom to the trunk floor. At this stage the frame is semi-ridged as it is attached only at the bottom. The top will be supported by a re-enforced lid. Note the foam tape in place to serve as a seal.

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Now the radiator is fitted onto the frame and sits upon the lower rubber shocks. The upper rubber shocks have been added at this point as well. Again, these were removed from the donor car and the OEM bracket was cut to fit and painted.

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The condenser is test fitted and the C shaped stand-offs are added to the top. These will have plate nuts for the lid to screw into and hold the radiator firmly in place and more importantly, to hold the radiator tightly against the seal on the frame.

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The 3/4" square tube is added, next to the stand-offs, that will have a rubber seal strip and complete the seal from lid to radiator. (It's also shown 2 pic's back.)

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And as it looks once buttoned up. I'm going to run this set up a few weeks w/o the condenser then re-install it to see how temps will vary. More later. beerchug.gif

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