Porsche 944: Actually there is a substitute

[sparkydog]

Next up is the starter circuit wiring. I created a little area behind the right strut tower for a place to be able to jump start the car without having to dive behind the seats to get to the battery. Also shown is my version of CAD. In this case "Commute Aided Design". This is where I dream up an idea while I'm commuting and then draw a sketch of it when I get out of the car. Some of the ideas stick and others don't. In this case I could not find an off the shelf jump start post that I liked so I ended up turning some simple black nylon parts on the lathe at work.

[sparkydog]

So then I went to try and bump the starter and got... nuthin!

In this picture I have +12v at the big post at the top of the starter. My engine ground is to the right where the starter bolt goes into the block. This cable then goes over to the frame. Then I hooked my remote start switch to the +12v big post and then the little post on the solenoid. Prior to doing this I verified that the start switch works. But once hooked up on the car nothing happens when I squeeze the switch. No clicks, no smoke, no bueno.

What am I doing wrong guys?

[sparkydog]

I figured out my issues trying to get the starter to bump. Nothing that cleaning all the grounds, actually tightening the starter mount bolts and getting a healthy battery couldn't fix!

[Palf70Step]

Sounds good. Glad you got it worked out. My brain was having issues thinking of something you hadn't account for.

[sparkydog]

Between scampering around dodging fires at home and work - I managed to get some more fabbery going. I mimicked the 944 shift boot ring but made a bigger one that would allow the shifter for the T5 to come out the top.

I also created some clearance pockets for the radiator.

[sparkydog]

A couple more.

[sparkydog]

Continuing along with the fabrication of the radiator mounting.
The first set of pics is making the bottom bracket - or what passes for a lower core support.

[sparkydog]

And then the two tubes that will become the posts onto which the bottom bracket will mount. The pics also show the little intricate pieces that became the ends of the bottom bracket. They allow the Ford radiator rubber grommets to sit into the bracket.

[sparkydog]

And then on to mocking it all up with the radiator, then scarfing out the necessary amount off the tubes - and then tacking, then welding the side braces into the car.

[Dirt Road Cowboy]

Brilliant!

[Palf70Step]

Very nice Sparky!

[sparkydog]

Originally Posted by Dirt Road Cowboy

Brilliant!

Originally Posted by Palf70Step

Very nice Sparky!

Thanks guys!

I don't know how long this link will work but check out this guy who has spent years on a build project! I mean... can you imagine what it's like to devote YEARS into something?

https://www.wired.com/story/why-one-...-out-of-paper/

[Palf70Step]

I think way more patience than I have.

[sparkydog]

And some more brackets! These are for mounting up the Mustang fan assembly to the 944. Of course I had to trim a the fan a couple of places. And it's now mounted "upside down" from the way it is oriented in the Mustang. But all-in-all it turned out pretty nice.

[sparkydog]

The only mods to the fan plastic was to cut off a chunk of 1 arm and also scallop a place to clear the 944 headlight popup shaft. (The picture shows my scallop marks before I cut them out.)

[sparkydog]

More brackets!!

Little rubber bumpers off GM W-body, then grafted into the 944 to help sandwich the radiator.

The arm things are the other half of the sandwich.

I even remembered to re-attach the nose skin on the 944 and make damn sure I could remove the radiator and fan assy from below without the convenience of having the nose open (like the way it looks in most of the pictures).

And I jumped the fan motor to the battery and verified the fan (from the donor Mustang) works OK and didn't make any bad noises.

[sparkydog]

And then two simple strap brackets to secure the Camaro air intake plenum thing.

Next was cutting a rather large hole in the firewall to allow the ECU connectors from the engine harness to pass thru into the passenger compartment.

[sparkydog]

And then of course some chair & stare time with a good cigar and a margarita!

[sparkydog]

There is no way the stock Camaro air filter box will fit into the 944 due to the Porsche popup headlight mechanism. I want an air filter box that is as OEM looking as possible but from some other make/model car.

So if any of you have suggestions for a mostly squarish air filter box that is about 11" long (fore/aft direction) x 8" wide (side/side direction) x 6" high from some donor vehicle, let me know!

[FRENCHBLUE72]

Good to see you still plugging away

[sparkydog]

Thanks French!

Some shots of the air filter box that I eventually used and the funky bracket I had to fab up to mount it. I will need to mod the box itself. It hangs low on one corner and I need to redirect the air entry passage up into the bumper area.

But progress is progress.

[Palf70Step]

Again, good to see some progress being made. Looking forward to see how it all looks together!

[sparkydog]

Hyundai power steering fluid tank goes in.

[sparkydog]

VW Jetta/Golf coolant expansion sphere.

[sparkydog]

More work on the connection tube between the Camaro intake plenum and the (whatever model) air filter box - all while dodging bits of the 944 headlight mechanism.