Introducing "Dirty Penny" - Former $2010[$2012] GRM Project, Running. Driving. Boosting. FUN! Options

[jpnovak]

I wanted to introduce myself as a new member to the World. I am new to the 914 but not new to air-cooled. I have two 1971 911s; a T - soft-window targa and an ST-replica track car. I am sure I have seen many of you on Pelican. With the 911 I have done it all, rust repair, paint, engines, transmissions and chassis setup. I felt it was time for something new.

Introducing my new project. "Dirty Penny"

Penny is a 1975 Porsche 914. She has been sitting unattended for a while. I found her at a friends house under the old oak tree. Penny is wearing copper metallic paint and had a white interior. Penny arrived without a heart. I am going to give her new life.

Penny will be built as a Grassroots Motorsports $2010 Challenge car. For those not familiar that means you have $2010 to build a car where it competes in a concours, drag race and autocross. The prize? Notoriety in GRM and ridicule from those who already think you are nuts and cheap. My wife doesn't affectionately call me Fred Sanford for nothing. (IMG:style_emoticons/default/smile.gif)

Here are a few pictures of Penny being unearthed from her previous home. The TX sun has not been kind to the paint, nor the interior. However, the dry climate has left her remarkably rust free. There is rust in the Hell Hole that has been previously cut out yet never welded back in. Rot is almost non-existent.

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How much money I have left to spend on the project.

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The plan is simple to do well at the Challenge. Get a car that handles well. Strip the weight out of it. give it some extra HP. Let's see... A 914 handles well. they are already pretty light. but the Type IV doesn't lend itself to high HP without major $$$.

A bit of late night ebay browsing and I came across a JDM Subaru EJ20G drivetrain. Yes, that's what I need. ITs still a flat-4 - yet has to be water cooled and makes 140+ HP/L in stock trim. I like it. The vendor was in Dallas which means reduced shipping costs. Yep, that's the rule. you must account for ALL purchases.

The new heart and soul... Oh yeah it will have soul!

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to be honest, work has been crazy and I have 13 months to build the car. Progress won't be fast. I am excited to make this go forward. The challenge of swapping the entire drivetrain begins with connections. The engine mounts are easy. Trying to get the shift linkage, clutch linkage and throttle cable done on the cheap is not so easy. I know there is a wealth of information on this site. Thanks to all those who have traveled this road before me.

Until the next update...

Now I have to figure out how to post images on this site rather than link external.

[jpnovak]

Penny is alive!! Despite the triple digit heat I was in the garage this morning.

The car runs despite lack of TPS, MAP and coolant signals. WooHoo!

Now I will finalize the wiring and finalize the injection system.

Next step is to fabricate axles and put a clutch connection.

[clow]

Penny is alive!! Despite the triple digit heat I was in the garage this morning.

The car runs despite lack of TPS, MAP and coolant signals. WooHoo!

Now I will finalize the wiring and finalize the injection system.

Next step is to fabricate axles and put a clutch connection.

This is a very neat concept. Nice to hear the car is running, congrats! Do you mind me asking what you have into it so far?

[jpnovak]

Currently, I am almost to ~$1900. Of course, almost $1450 is in the drivetrain. I bought the roller for $300. The difference is for steel tubing to build the engine cradle and fix rust. I will post a full detailed list once I am done.

I am going to have to swap my interior budget (seats and "carpet") to convert to hydraulic clutch. Just the parts will be close to $75 for a used MC/hose and banjo fittings. Thank goodness fabrication is free.

The only thing i will not count in the build budget is for a few safety items. Mostly this is new brake hoses and caliper rebuild kits. I will not take a car out without going through the braking system with a fine tooth comb. I might even replace the MC. First I will just pull it apart and check for pitting/wear on the bore/piston. Yes, this is within the rules. I will also replace the stock belts with a harness.

[jpnovak]

FYI, I just moved a work trip and am now clear for the tow from TX to FL for the event. I have less than 4 weeks to complete the car. There will not be much time for updates but I will try to mark off the list.

I will follow up with a complete build post once this is all over.

Tonight I finalized my hydraulic clutch setup. I just have to make final connections to the pedal cluster and connect a supply line off the brake reservoir. Rock and Roll!

Brakes are completely rebuilt with new rubber lines.

I have to connect a throttle cable and put rubber on the car and I should be able to drive it within the next week. I am getting really close now.

After the car is running I need to sort the suspension (align and corner balance) then install a seat and my "special" interior. Really, there is nothing special about it. Just some lightweight carpet to hide bare panels.

[SirAndy]

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[rick 918-S]

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[jpnovak]

22 days left! That's it to complete a long list of stuff.

Weekend progress.

1. Hydraulic clutch is completely plumbed. fluid flows with no leaks
2. Hydraulic clutch is connected to pedal cluster - pedal actuates MC
3. Hydraulic clutch does not work - needs to bleed!
4. Brakes are full of fluid - No leaks after the rebuild. (well there was two lines I forgot to tighten on the passenger side front.
5. rocker panels are painted.
6. Front bumper screen is epoxied into place to protect the radiator. John, thanks for the aluminum screen from the satellite. It works perfectly.
7. Front bumper is blocked and painted. Unfortunately I will need to repaint. I did not know it was so hot yesterday afternoon. The paint was drying as I was brushing. Usually Rustoleum flows really well to level itself. However, it does not flow when its 104. I did not realize it was so hot until late last night.


Next up

1. Must get tires mounted
2. get throttle cable connected -
3. Waiting for final plugs for radiator. Still "in transit"
4. Connect, fill and leak check cooling system.
5. Determine seat/harness arrangement -
6. Install Harness
7. Weld final struts on motor mount to prevent fore/aft swing and rock of engine under power
8. weld cable mounts for shifter on tranny mount
9. Paint tranny and engine mounts
10. remake shifter to cable stop mount (I don't like the current one - holes are too big; too much slop)
11. Make connection to alternator
12. Find alternator belt that fits.
13. Carpet interior

[jpnovak]

Crossing things off the list...

14 days and counting.

1. Must get tires mounted
2. get throttle cable connected -
3. Waiting for final plugs for radiator. Still "in transit"
4. Connect, fill and leak check cooling system.
5. Determine seat/harness arrangement -
6. Install Harness
7. Weld final struts on motor mount to prevent fore/aft swing and rock of engine under power
8. weld cable mounts for shifter on tranny mount
9. Paint tranny and engine mounts
10. remake shifter to cable stop mount (I don't like the current one - holes are too big; too much slop)
11. Make connection to alternator
12. Find alternator belt that fits.
13. Carpet interior

the clutch is still not working. I am having problems getting it to bleed properly. Tonight I will pull out the vacuum bleeder and get to work.

My cable shifter is awesome! It shifts with a simple, authoritative snick that my friend compared to a motorcycle. The positioning of the shifter is in perfect relationship to the steering wheel. I can't wait to get seats in place and test drive. Maybe tomorrow night.

[jpnovak]

The competition has just been announced. Compare and Contrast!

Lots of interesting cars. It will be fun to check out what is unique about each one. From previous event coverage the small hondas and such have big turbos and turn quick 1/4 mile times. Same can be said for the big V8 cars.

I might have the only mid-engine turbo car there. Of course, people relocate drive trains and there are many creative builds. I can't wait to see what happens.

Condor Speed Shop Carlos Mendez 1975 BMW 2002
Gary Wyatt 1987 Chevrolet Corvette
Hendricks Motorsports James Hendricks 1983 Jaguar XJS
Mickler Motorsports Philip Mickler 1980 Ford Fiesta
Nelson Family 1
SDAC Patrick Culkin 1988 Dodge Arries
Roadcat Racing Doug Qualls 1985 Mazda RX-7
Shane Samuels Go Fast or Die Trying 1975 Datsun 280z
Nanoman's Garage James Novak 1975 Porsche 914
Evil Ducky David Melton 3000 Mach 1.5
O-Town 350s Joseph Thompson 1974 Datsun 280Z
OMGWTFBBQ Edwin Rodriguez 1991 Eagle Talon
Git R Dun Mattew Wojtkowiak 1994 Pontiac Firebird
El Diablo Speedshop Marc Griswold 1986 BMW 325e
Milton Robert Branch 1988 Toyota Supra
Erroneous 1 Sammy Shams 1985 Nissan 300zx
Backyard Bessie Kevin Sweeney 1998 Saturn SC2
3 Guys from Canada Jonathan McCreery 1997 Honda Civic CX
Hello Kitty Spinout Lasota 1975 Triumph TR7
Black and sTan Adam Baskin 1992 Mazda Miata
Roadstein Racing Jason Stanford 1994 Mazda Miata
Busted Knuckle Racing Brian McGarvey 1988 VW Scirocco
Sparkly Unicorn Farts Scott Evans 1991 Honda Civic Nelson Family 2
BURP Trip Ferrer 1992 Honda Civic
Hong Norrth Les Burchett 1986 Honda CRX
Hong Norrth Les Burchett 1985 Dodge Omni GLHT
Project: Parts Bin Bryce Nash 1972 Honda N600
Whim Racing Greg Voth 1977 Triumph Spitfire
Uranus Mike Guido 1986 Mitsubishi Uranus
wreck racing Team Gimp John Hooper 1987 Dodge Charger
Erroneous 2 Thomas Jaeger 1989 BMW 325is
CH Racing Tim Spellman 1987 Pontiac Firebird
The Killer Team
Time Racing Chris Simmons 1984 Chevrolet Corvette
Andrew Neuman 1990 Honda Civic Si
Dorsey Brothers Stan Dorsey
Westside Brian Dimont 1992 Eagle Talon
Karl Lafollette
Karl Lafollette
FOAB Ben Berusch 2001 Mazda Miata

[rick 918-S]

Cool! Be sure to post pics of your competition! (IMG:style_emoticons/default/aktion035.gif)

[jpnovak]

9 days and Counting...

It appears that this project kept going despite my life's best attempt at keeping me from completing it. 9 days from now I will load up and two to FL for the GRM $2011 Challenge.

The car drove on its own for the first time in 10+ years. Runs a little rough but all systems are working. I just have to start sorting the car in the next week, get it cleaned up and ready for action.

A few pictures of the car back on four wheels.


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Here is a short list of the project.

1975 914
1998 Subaru EJ20G 2.0T engine
Subaru 5sp manual transmission
hydraulic clutch conversion
stripped to the minimum
GT style front bumper


Let's just say that its light enough and has enough torque that it can start in 4th gear. yeah, I just found that out since my shifter is backwards in the LR plane. I have to reverse cable connection.

this week I will cut and buff the paint, layout the graphics, install the rockers.

I need to install a cooling system overflow tank. Right now I have no way to control the heat expansion.

Also, I have to roll the rear fenders. The 205/50 tires rub.

Also, I need to install a harness and seat. The seat is just sitting on the floor for now. It made my test drive quite fun.

I will post updates at the event. I will update with a full build after the event.

[rick 918-S]

I'm excited for you. Good luck! Be sure to nut and bolt that thing before you try to shake it down for the first time. I would hate to see you get a DNF for a silly missed bolt or a hose or a wire rubbing through some place.

[jpnovak]

Agreed. A nut and bolt effort is on the list. Everything from motor mounts to CV axles to simple things like light and seat mounting bolts.

I wish I had more time to sort the car.

Either way, I will have a blast and have loved building this car.

once I finish the event I have to determine if I keep it for a DE car or move on to something else. I can say that my wife would like to see one of the cars go...

[rick 918-S]

If I was in Texas (IMG:style_emoticons/default/smash.gif) (IMG:style_emoticons/default/sawzall-smiley.gif) I would be over to help you. I'll be watching (IMG:style_emoticons/default/popcorn[1].gif) and cheering you on! (IMG:style_emoticons/default/aktion035.gif)

[jpnovak]

Ahh Texas where at the end of September it was 105 yesterday.

Hard to keep motivation up when working in the garage sweating all over the car.

[jpnovak]

Despite another heat wave and hectic work schedule I managed to get the paint buffed. 15 minutes a panel spread over many hours can really accomplish a lot.

I am really starting to love the copper metallic color.

Also, I fixed the shifter by reversing the travel. Works much better now. I can even select all 6 gears. Yes that includes reverse.

Bad news, my home made rear differential cover plate leaks at the bottom. I guess I need to pull it and reseal.

[Brett W]

What did you do about the axles? Did you have the splines re-cut to allow the use of the Suby inner joint? Looks like you could have a potential winner on your hands. If you keep the car for next year you can sort it out and make it better.

[jpnovak]

The Subaru and 914 axles are the same diameter (+/- 0.5mm). I cut and welded the center of the axles and then welded a sleeve over the weld joint. The result is a hybrid subaru inner / 914 outer.

I suspect these should be strong enough for the event. Custom axles or the custom flanges might be a better option. However traction on the tires will be my weak point during the event.


jigged
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welded and finished
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sleeved and welded
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[Brett W]

You might paint a white line the length of your axle shafts to make sure they don't twist. It would give you a pretty quick safety inspection through the weekend. Good luck.

[jpnovak]

Great suggestion.

I was going to have them heat treated but could not find a vendor locally that could turn them around fast enough. I would love to have them rehardened.

if they survive the weekend I will harden them after the event.