914 GT 3.6 Ferrari Build, - Mechanicals coming along, electronics soon! Options

[Mueller]

I like that exhaust solution, pretty slick!

$35K for the conversion kit and I think that is for parts only and they must do the install, figure another $10K or so.

[ClayPerrine]

The biggest issue I had with my Boxster trans adapter was the flywheel. A 964 uses a pull type clutch.
A Boxster uses a push type clutch. Making an adapter to fit a push type pressure plate to a 964 flywheel took some work. And a 944 turbo racing pressure plate. I would love to find a Boxster flywheel that would bolt to a 964 crankshaft.

The second issue was the starter. Not making a hole, but adding a mount in the right position so the starter would engage without grinding or sticking.

There are pictures in my build thread. I posting from a cell phone and can't get the link.

Clay

[tygaboy]

While I'm pretty good with my 2D CAD program, I've not spent any time in the 3D world. So after playing around with that file, I chose a far faster path and contacted @Mueller . Let me give a HUGE thanks to Mike for jumping right on verifying the file, dimensioning it for me and going the extra mile to locate a Boxster engine file and doing a quick overlay.
Yes, I have all the 3rd D to work out but this is a really big help to get me going.

Let me say it again: Mike - THANKS!! Simply couldn't do it without you. (IMG:style_emoticons/default/aktion035.gif) (IMG:style_emoticons/default/pray.gif)

[Mueller]

No problem at all, this is almost like owning a 914 again without the cost or heartache (IMG:style_emoticons/default/smile.gif)

[tygaboy]

If I'm going to have any hope of having this running for WCR 2023 (IMG:style_emoticons/default/driving.gif) , I better get back at it.
My LS car is back on the road so the Ferrari build is back in the Red Barn. Today was spent fine-tuning the drive train location and taking final measurements so design, fab and welding can begin on the trans and engine mounts.
The trans mount cross bars and hanger are almost ready to be welded in - can't hardly wait!
But waiting is sometimes a good thing: Remember how excited I was to see the header in place, "just" moved up one cylinder? Good thing I didn't get too excited. Turns out that with the adjustments I made to get the drive train in optimal position for the axle height, that modded header no longer fit! Everything got lowered by about 3/4" and that was all it took for the header to, once again, foul on the suspension console. What to do? (IMG:style_emoticons/default/idea.gif) Well, if moving things forward by one cylinder helped the first time, I gambled it'd help again.

And it did. It actually looks better, too. The primary tube bundle nicely fills the area outboard of the front cylinders and I gain even more length for the post-collector exhaust.
In this location, there's more room under the bundle to re-route the two tubes that need to be re-connected to the flange.
As before, the collector still needs to be sliced off and clocked to clear the rear of the cylinder head. But overall? Win-win! (IMG:style_emoticons/default/aktion035.gif)

[tygaboy]

The under side, not that anyone will ever see this view...

[tygaboy]

Let's make some parts, eh? Here's the final design for the transmission hangers. One will live on each side of the trans mounting tab. Fabrication is underway!

[tygaboy]

Let's back up and get a better view of the "two forward" header. As mentioned, it nicely fills that area outboard of the front of the heads but will need re-clocking of that last section where it will join the rest of the exhaust.

That odd fastener sticking out of the collector? I'm told that's an EGT sensor location. Not sure if it was used on euro cars or the Stradale maybe but that's how these headers came to me...

[tygaboy]

Speaking of the exhaust, even though I can't use the factory muffler, the muffler bracket looks like it can be used. It mounts to the trans but is too long for the 914. A little sectioning (it originally had two of those oval holes in the outside walls - I removed one) and we're all set.

[ClayPerrine]

[tygaboy]

Transmission mounts nearly done, courtesy of Martin, his skills and machine shop. We make a pretty good team: He's got a great eye for design and unmatched fabrication talents - and I've got projects that need those things! (IMG:style_emoticons/default/laugh.gif)

It starts as a 9" length of 1" x 3", .095 wall tube. It's interesting what comes up when moving from "how about we do this?" to actually making the parts. In this case, the design for these hangers changed because as the material was cut away to get the cool tapers on all the different surfaces, the remaining material wouldn't stay in plane during the follow-on machining operations. So the taper on the 3" face had to start farther from the lower hole than originally planned. In the end, no one will know and even I didn't notice until Martin pointed it out to me.

With a bit of luck, the trans mount will be in the chassis in the next couple days!

[tygaboy]

Wrapping up the wrap-around on the 2nd hanger then they both get a 2" hole and a final tidy up. A couple days of work. Worth the effort just so the hangers end up with a few style points?

Oh, hell yeah! (IMG:style_emoticons/default/aktion035.gif)

[tygaboy]

Test fitting the transmission mount. That bit of paper is just to model the "insert" that will close off the inner area of the hanger tubing. I wanted to see these in the car and determine if they really needed the insert. Yep, they do.
But other than that, I'm super happy with how they turned out! They are LOVELY. (IMG:style_emoticons/default/wub.gif)

And can I just say: It's so great to be working with Martin again. (IMG:style_emoticons/default/smilie_pokal.gif)

[tygaboy]

As much as I generally like the full mechanical, simple look, I'm not a fan of the gap between the hangers, purposefull though it may be. I cardboarded up a few different cover panels - one that ran side to side of the hangers with a single, large dimple die hole, one that sat on center of the tubes, just between the hangers...
Then this one showed up and I think it's the winner.
It'll be removable, too, which means it could be made of nearly any material. (IMG:style_emoticons/default/idea.gif)

[Chris914n6]

[KELTY360]

So clean and so beefy. I like the unadorned look that shows the fabrication detail. A spot where function is beautiful.

[partwerks]

more

Is that a Chief Automotive frame machine? Those rectangular holes sure look familiar.

[tygaboy]

As usual for me, we're way far away from 914 content but I assume many of you enjoy this sort of thing.
Here's another look at just how time consuming custom fab can be. These are "just" the transmission mount hangers, as I've come to call them. Look back at what Ferrari used: essentially, just two plates with a break along one edge. These could have been largely the same and that would have taken almost no time to make. But I suspect you all know that simply wouldn't do, because, well, Tygaboy and Style Points! (IMG:style_emoticons/default/laugh.gif)
So, along with all Martin's fancy pie cutting, welding and dressing to get those lovely tapers and a factory-looking edge radius all around the hangers, I asked him to close up the open area of the tube created when that cool shape of an opening was made in the outside wall.
A bit of 18 ga sheet metal trimmed and bent to fit and we have the wall.
That gets clamped in place, tacked all around and trimmed, leaving enough proud of the surface to fuse weld to the outer wall of the hanger.

[tygaboy]

Both sides all set for fuse welding and final dressing. After that, these lovlies get welded to the cross bars and into the chassis.

All said, there'll be over 20 hours into making these. Call your local fab guy to get an hourly rate and do the math...

Forgetting cost, folks generally have no idea of the time it takes to do one-off stuff like this.

But just look at those things. (IMG:style_emoticons/default/wub.gif) Works of art.

And I have to say: TOTALLY worth it!!

[horizontally-opposed]

Gorgeous work, Chris! (IMG:style_emoticons/default/shades.gif)