Show full size 924Board.org
Discussion Forum of 924.org
 
 FAQFAQ   SearchSearch   MemberlistMemberlist   UsergroupsUsergroups   RegisterRegister 
 ProfileProfile   Log in to check your private messagesLog in to check your private messages   Log inLog in 
 Technical FAQ924 FAQ (Technical)   Technical924 Technical Section   Jump to 924.org924.org   Jump to PCA 924 Registry924 Registry

Fitting a Late (Plastic) Fuel Tank to a 924S
Goto page 1, 2  Next
 
Post new topic   Reply to topic    924Board.org Forum Index -> How-To
View previous topic :: View next topic  
Author Message
Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11329
Location: PacNW

PostPosted: Sun Jun 28, 2009 10:37 am    Post subject: Fitting a Late (Plastic) Fuel Tank to a 924S Reply with quote

I recently pulled the tank out of Red to check out fuel leakage problems, and sure enough, she was leaking at the stampings on top as typical (discussion at Pelican Parts). The "expansion tank," i.e., plastic tube of mystery was also cracked. Yes, I could have the tank repaired, and get new plastic bits from Germany, but by the time I was done, that would end up costing me two bills.

Coincidentally, a buddy of mine was parting a 951, with the later plastic tank. I jumped on the opportunity to do the swap, rid myself of a leaky, and liner-shedding steel tank, and give myself a hefty 22 gallons of capacity.

The steps are:

  1. Get tank, pump, filter bracket, trans xmember, tank straps, strap brackets, and standoffs from the donor. Make mounting templates or take measurements for the strap brackets.
  2. Excise welded in toofah crossmember, magically revealing mounting points for xmember and tank straps (applies to 924S only).
  3. Weld in brackets, standoffs.
  4. Install tank, and tranny using updated center "dangle" mount.
Next, introductory pics. . .
_________________
Toofah King Bad
  • Shaggy (1980 931) - Got Boost?
  • Red (1987 924S) - Pro44/Spec944
  • Weiße Scheiße (1987 924S) - In Progress
Back to top
View user's profile Send private message Visit poster's website
Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11329
Location: PacNW

PostPosted: Sun Jun 28, 2009 10:47 am    Post subject: Reply with quote

951 v Toofah, Left End of Crossmember:




Right End of Crossmember:




951 v Toofah Spare Tire Well:




Next, creation of bracket template, removal of strap brackets. . .
_________________
Toofah King Bad
  • Shaggy (1980 931) - Got Boost?
  • Red (1987 924S) - Pro44/Spec944
  • Weiße Scheiße (1987 924S) - In Progress


Last edited by Rasta Monsta on Sun Jun 28, 2009 11:15 am; edited 1 time in total
Back to top
View user's profile Send private message Visit poster's website
Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11329
Location: PacNW

PostPosted: Sun Jun 28, 2009 10:59 am    Post subject: Reply with quote

Start with a 12x26 piece of cardboard. Jam it tightly into the corner as shown here:



For convenience sake, trim it down to a semi circle. Also remove a bit of the corner if there is a big blob of body sealer/undercoating in the corner of the body:



Brackets, meet Mr. Angry Grinder, and his new friend, The Wire Wheel of Death.





That wire wheel made extremely short work of the undercoating material. Easy breezy!

Next, measure out the positions of the brackets (from TOP and car's RIGHT), and mark them on your template. Now remove the brackets using a spot weld cutter.




With the brackets in hand, their precise shape can be traced onto the template, and holes cut with a box cutter. Double check your work by holding the template in place on the donor car:




Next, turning your x-member into an x-x-member.
_________________
Toofah King Bad
  • Shaggy (1980 931) - Got Boost?
  • Red (1987 924S) - Pro44/Spec944
  • Weiße Scheiße (1987 924S) - In Progress


Last edited by Rasta Monsta on Fri Jul 24, 2009 2:31 am; edited 1 time in total
Back to top
View user's profile Send private message Visit poster's website
ic932  



Joined: 11 Feb 2005
Posts: 1104
Location: UK

PostPosted: Sun Jun 28, 2009 7:43 pm    Post subject: Reply with quote

Top Man...excellent write-up Rasta.

I can see you have exciting plans for Red huh?
Back to top
View user's profile Send private message Send e-mail
mvallee  



Joined: 09 Feb 2006
Posts: 62

PostPosted: Fri Jul 03, 2009 11:49 am    Post subject: Reply with quote

Lookin Good!
Back to top
View user's profile Send private message
Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11329
Location: PacNW

PostPosted: Mon Jul 06, 2009 4:48 pm    Post subject: Reply with quote

Huge thanks to mvallee, who has answered a bunch of my questions over at Pelican.

Also, he is creating a 951 powered GTS, and if we all bug him about it, he might share some of the details. . .and PICS!
_________________
Toofah King Bad
  • Shaggy (1980 931) - Got Boost?
  • Red (1987 924S) - Pro44/Spec944
  • Weiße Scheiße (1987 924S) - In Progress
Back to top
View user's profile Send private message Visit poster's website
Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11329
Location: PacNW

PostPosted: Fri Jul 24, 2009 2:41 am    Post subject: Reply with quote

And now, to hack out that crossmember.

Did you know they made metal cutting wheels for a Skil saw?



PROTECTION IS EXTREMELY IMPORTANT!



Yeee-haw!



Thankfully, there really were bolt holes under the crossmember!



UGLY v. PRETTY



Whew! Next, prepping and welding in tank mounts. . .
_________________
Toofah King Bad
  • Shaggy (1980 931) - Got Boost?
  • Red (1987 924S) - Pro44/Spec944
  • Weiße Scheiße (1987 924S) - In Progress
Back to top
View user's profile Send private message Visit poster's website
ideola  



Joined: 01 Oct 2004
Posts: 15460
Location: Woodstock IL

PostPosted: Sat Aug 08, 2009 2:54 pm    Post subject: Reply with quote

Hey Rasta, I want to add a section in the performance upgrade thread referencing your conversion. Out of curiosity, what was your primary motivation for doing this? I know the plastic tank is lighter and higher capacity, and you had the cracking issue on the original...any other considerations I should mention? Also, how about an update...any recent progress?
_________________
15 981 GTS | 88 924S SE | 82 931 Holbert | 82 931 Rallye | 81 937 | 81 Euro 931 | 81 Weissach | 80 US 928 | 80 US 931 '941' | 80 US 931 | 80 931 GTR | 79 Sebring | 78 D-Prod Replica | 78 w/D-Prod kit | 78 Poli-Form | 78 Limited Edition | 77 Martini
Back to top
View user's profile Send private message
Chrenan  



Joined: 15 Jan 2003
Posts: 3899
Location: Canada

PostPosted: Sun Aug 09, 2009 1:09 am    Post subject: Reply with quote

951 tank is HUGE. 90 litres I think.
_________________
1987 951 - M193 Version for Japan
Back to top
View user's profile Send private message
Paul  



Joined: 02 Nov 2002
Posts: 9279
Location: Southeast Wisconsin

PostPosted: Mon Apr 12, 2010 10:10 am    Post subject: Reply with quote

Rasta, is it just me, or are the pictures gone?
_________________
White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Back to top
View user's profile Send private message Send e-mail
Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11329
Location: PacNW

PostPosted: Mon Apr 12, 2010 3:36 pm    Post subject: Reply with quote

Corrected.
_________________
Toofah King Bad
  • Shaggy (1980 931) - Got Boost?
  • Red (1987 924S) - Pro44/Spec944
  • Weiße Scheiße (1987 924S) - In Progress


Last edited by Rasta Monsta on Tue Apr 13, 2010 11:55 am; edited 1 time in total
Back to top
View user's profile Send private message Visit poster's website
Paul  



Joined: 02 Nov 2002
Posts: 9279
Location: Southeast Wisconsin

PostPosted: Tue Apr 13, 2010 10:48 am    Post subject: Reply with quote

C'est bien dommage.
_________________
White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Back to top
View user's profile Send private message Send e-mail
Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11329
Location: PacNW

PostPosted: Tue Apr 13, 2010 11:11 am    Post subject: Reply with quote

Use the template to mark the area the tank brackets will go on the spare tire well:



Then put Mr. A.G. back to work:



Same for the upper "hanger" mounts, which center perfectly into the round areas stamped into the cargo floor. PLEASE NOTE THAT THE STANDOFFS WERE REMOVED FROM THE SQUARE CUT OFF BITS IN THE PIC BEFORE INSTALLATION.




This guy brought his 120v welder over, and did the job pretty inexpensively:



Next: fuel lines.
_________________
Toofah King Bad
  • Shaggy (1980 931) - Got Boost?
  • Red (1987 924S) - Pro44/Spec944
  • Weiße Scheiße (1987 924S) - In Progress


Last edited by Rasta Monsta on Tue Apr 13, 2010 11:57 am; edited 1 time in total
Back to top
View user's profile Send private message Visit poster's website
Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11329
Location: PacNW

PostPosted: Tue Apr 13, 2010 11:28 am    Post subject: Reply with quote

Fuel line routing was a bit of a pain, but not insurmountable. First, the feed line, shown here with rubber intermediate line attached:



PLEASE NOTE THAT I SWAPPED THE POSITIONS OF THE FEED AND RETURN LINES IN THE ABOVE BRACKET, AS THE FEED LINE NEEDS TO DROP DOWN AROUND THE FRONT OF THE TANK NEAR HERE. WHEN YOU DO THIS, YOU MUST ALSO INSULATE THE TWO LINES FROM ONE ANOTHER WITH RUBBER AT THE POINT THEY CROSS TO AVOID DAMAGE FROM RUBBING!

On the 951, the fuel filter is mounted on the crossmember, and the feed line to the front of the car (via metal hardlines) leaves it by way of a special fitting, which then transitions into a rubber hose. You can see the rubber section in the stock feed line in the photo, also requiring a special fitting.

These two different ends need to be on the same line, so I fit the crossmember to the car, and used a couple of zip ties to attach the rubber sections to each other, side by side, along the path they would need to take from hardline to filter mount. I then disconnected the lines, and took them (still zip tied together) to the hose shop to have a custom line made up, of the correct length and with the correct ends to "blend" the two systems. Easy peasy!

Next the return line:



The 951 fuel return goes into the TOP of the tank near the sender. In the pic above, the line basically needs to do a 90 degree turn right around that fastener, and along the path of the stamping you can see leaving the top of the pic. I thought about trying to bend the line, but my pals at the hose shop recommended the line be cut, and a compression fitting used instead. A 90 degree barb was then screwed onto the compression fitting, and a piece of hose pressed onto the barb, and attached to the tank on installation.

Next, spend five minutes installing the fuel tank. You can't imagine how much easier this is without that stupid crossmember in the way.

DONE. Red no longer stinks of gas, has a better tranny mount setup, and holds 20+ gallons of fuel.
_________________
Toofah King Bad
  • Shaggy (1980 931) - Got Boost?
  • Red (1987 924S) - Pro44/Spec944
  • Weiße Scheiße (1987 924S) - In Progress


Last edited by Rasta Monsta on Tue May 11, 2010 5:14 am; edited 7 times in total
Back to top
View user's profile Send private message Visit poster's website
Paul  



Joined: 02 Nov 2002
Posts: 9279
Location: Southeast Wisconsin

PostPosted: Tue Apr 13, 2010 11:37 am    Post subject: Reply with quote

Merci beaucoup!
_________________
White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Back to top
View user's profile Send private message Send e-mail
Display posts from previous:   
Post new topic   Reply to topic    924Board.org Forum Index -> How-To All times are GMT + 11 Hours
Goto page 1, 2  Next
Page 1 of 2

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum


Powered by phpBB © 2001, 2005 phpBB Group