Finishing A 914-6 GT Conversion Project, Great Start, But The Devil Is In The Details! Options

[Lucky9146]

Dust off the trans.

Note that the trans had been gone through and intermediate plate added for 914-6, a new gear, bearing, and gaskets while under PO moparrobs ownership. Should be ready to go!



Next is the trans shift arm fix recommendation that comes by way of Forrestkhaag.

It’s a 10 cent fix!

He called it "the shaved head dime". Yes it takes a bit to file it down to fit in the cup hole.

Do yourself a favor and do a search and check out forrestkhaag’s posts regarding trying to resolve shifting issues on his 914-6 conversion. He truly has been through the wringer. Best of all his tip came to me via a PM from him on another subject, he just offered it. I definitely took his advise even though I already had the new bushing installed, yup I dug out a brand new never used bushing and ordered another. They do not like to come out nicely either! Scraped the arm all up trying to get the dang bushing out.

The story is that after fighting gear “nash” issues Leamon gave forrestkhaaag the same advise and it fixed it!

This is a great site!

[lonewolfe]

Replace the bushing with a dime?

[Lucky9146]

Replace the bushing with a dime?

Oooops sorry wasn't clear no insert the dime then install the new bushing. It is working to space the bushing up a bit is all. Changes the arm position closer to the clutch.

[lonewolfe]

Replace the bushing with a dime?

Oooops sorry wasn't clear no insert the dime then install the new bushing. It is working to space the bushing up a bit is all. Changes the arm position closer to the clutch.

That makes more sense to me. Is this mod only for the 914-6 or for 914-4's as well?

[Lucky9146]

Replace the bushing with a dime?

Oooops sorry wasn't clear no insert the dime then install the new bushing. It is working to space the bushing up a bit is all. Changes the arm position closer to the clutch.

That makes more sense to me. Is this mod only for the 914-6 or for 914-4's as well?

May have to defer to someone with a lot more experience on that possibly Leamon who I do not know but advised forrestkhaag. I will see what else I can learn. Fair question though.

[gms]

Replace the bushing with a dime?

Oooops sorry wasn't clear no insert the dime then install the new bushing. It is working to space the bushing up a bit is all. Changes the arm position closer to the clutch.

That makes more sense to me. Is this mod only for the 914-6 or for 914-4's as well?

the lever arm is the same on both 914/4 and /6

[Larmo63]

I didn't do the dime bag trick and my clutch is fine.

Just saying.

[Lucky9146]

I didn't do the dime bag trick and my clutch is fine.

Just saying.

Glad you got yours running yesterday! (IMG:style_emoticons/default/driving.gif) Nice work!
Oh well maybe it will help mine. (IMG:style_emoticons/default/confused24.gif)

[porschetub]

I didn't do the dime bag trick and my clutch is fine.

Just saying.

I think this modification would suit those who have machined flywheels (IMG:style_emoticons/default/confused24.gif) ,I would say that a shim washer under the pivot ball would do the same thing,I don't really know if there is enough thread to support that,surely would do the same job.
Reason I mentioned as I believe I have the same issue as forrest had but to a lesser extent,just feel like the lever isn't moving enough.......
At the moment I live in hope my trans isn't (IMG:style_emoticons/default/stromberg.gif) .

[Maltese Falcon]

I didn't do the dime bag trick and my clutch is fine.

Just saying.

Lawrence...I think the 914World has the best nicknames around any of the car forums; Dime Bag (too funny / as in Ceech + Chong), taco plate, hell hole, narp...Not Hijacking this thread; back to your scheduled program (IMG:style_emoticons/default/biggrin.gif)
Marty

[Lucky9146]

Kennedy Conversion Flywheel and Kennedy Stage II Clutch back in place.



Trans and starter back on, the last 2 pieces of sheet metal, and finish the Perry Kiehl wiring harness hook up.

Now on to addressing the intake manifolds.

[Lucky9146]

Porting my brand new intake manifolds.

Wow, these new manifolds sure look nice! And I’m going to grind on them? (IMG:style_emoticons/default/WTF.gif)
This operation does not sound like fun. Porting is a new one to me and one problem I have is that while I like doing most things once so doing anything 6 times is pure torture. (IMG:style_emoticons/default/head_hurts_kr.gif) Ugh!




PO was generous enough to mail me his “porting kit”. How’s that for support! Thanks moparrob!! No more excuses now I have to do it!



To start with, I just have to say that I was concerned about tackling this project with brand new manifolds as they were quite an investment and not something to screw up!
I am sure there are many out there that have done this and it would be no biggie to them.
So here goes……………..

I was looking for something around the house to use to model the ported hole size to and it turns out that a ping pong ball is almost exactly the correct size I need. Who knew? Disclaimer: I didn't realize that I had only 3 China ping pong balls to choose from.
That's the insulator and the diameter I am going to be working to.



Transfer insulator diameter to manifold, and you can see the difference in size and how much material has to come out with no gouges or scarfing up the flange surface! No Pressure!!!!



More to come................................

[mepstein]

Get a scap piece of aluminum, cut a hole in it. Them work on "porting" it. Always practice a new procedure on scrap before you do the real thing. Pretty universal.

[Lucky9146]

Tried starting with grinding wheels, first the one from the kit. Yup loads right up just like I thought it would with aluminum. I think it was meant to grind on a Chevy manifold. I even resurrected a coarse stone that I had from eons ago. And that one loaded right up too!


Well this ain’t working. So off to the hardware store and search for a solution. Came up with this jewel of a carbide rotary file burr tool FOR ALUMINUM. What a great find! The girl at the hardware store even remarked “isn’t it pretty?” and I had to agree. $33.00 pretty. Didn’t even need that grinding wheel in the picture it was only for back up.


Man that burr tool is amazing but I can see how you can get in big trouble real fast though. Slow and easy but it cuts like butter. Runner finish is a close match to as new, actually got it even closer after this pic.
Enlarged runner in process left and original runner right.


Developed a process which yielded a good runner finish very close to what the manifolds came with by using these tools in this order left to right.
Carbide burr, 60 grit roll, 80 grit roll, coarse scotch brite and fine scotch brite.


Not so bad just tedious and time consuming plus knowing there are 6 total to do.

[Lucky9146]

Get a scap piece of aluminum, cut a hole in it. Them work on "porting" it. Always practice a new procedure on scrap before you do the real thing. Pretty universal.

Thanks for the tip Mark but I had so much material to remove that there was plenty of practice right in front of me. Start off slow is all. Have plenty of wood working experience in shaping just different tools and material is all.

Going well more to post and that is time consuming too but I wanted to share this experience.

Thanks for weighing in.

[mepstein]

Get a scap piece of aluminum, cut a hole in it. Them work on "porting" it. Always practice a new procedure on scrap before you do the real thing. Pretty universal.

Thanks for the tip Mark but I had so much material to remove that there was plenty of practice right in front of me. Start off slow is all. Have plenty of wood working experience in shaping just different tools and material is all.

Going well more to post and that is time consuming too but I wanted to share this experience.

Thanks for weighing in.

If you have wood experience then you are ahead of the game. You already know it's easier to remove than put it back. Good luck.

[moparrob]

Looking awesome. I'm glad someone is putting those porting tools to good use.

[Lucky9146]

[quote name='moparrob' date='Sep 7 2017, 12:11 PM' post='2525302']
Looking awesome. I'm glad someone is putting those porting tools to good use.
[/quote

Thanks Rob!

These are billed as 40/36 manifolds but they actually measured 35mm so I am really going from 35 to 38mm.
It is a lot of alum to remove and that carbide burr works perfect for this job!.

In process on right side


Metal removed from just one runner


The ping pong ball fit check

[Lucky9146]

First hole done!

That would be the obviously larger one in the center.


How it matches up to the insulator



And before and after with the ping pong ball really gives sense of the size. Yes that is the same ball.



OK now just 2 more runners on this manifold with no mistakes!
Working good so far........

[mepstein]

Liar ! You've done this before. (IMG:style_emoticons/default/biggrin.gif)
Or it least it looks that way (IMG:style_emoticons/default/beerchug.gif)