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My 924 Turbo, metal 3D printing !
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Cedric  



Joined: 27 Aug 2004
Posts: 2697
Location: Sweden

PostPosted: Sun Aug 18, 2024 2:52 am    Post subject: Reply with quote

Well this wasnt a very well uppdated thread Last year got lost because the engine was blue smoking alot when it was finally started up, after tearing down alot of stuff, including removing a piston (shitty job) removing the head (also a shite job) and the conclusion was that there was a score in one of the valve guide bores, from either when they were pulled out or in. The company who did the engine work fixed it, but it sucks since i lost a driving season pretty much.

Anyway, its on the road now, and I had a few test drives, to continue to get some driving time on the engine. Ive also had a few fun test drives on twisty roads to try the new GAZ gold suspension.

Current status

Engine:
I had some issue with a weird rev hang when it got warm, disconnected the decel valve and it disappeared , very strange.

It pulls really well, and it will not be very long run in process, i mean 0,7 bar is part load now that i can run 1 bar of boost:) The last oil i took out was crystal clear, so i think not much more will happen from now on.

The fuelling which have always been rock solid since 2009 or whatever year i started driving it properly have now jumped a whole step in AFR, which means its running pretty rich. With the boost line to the wur unhooked (ive had that before aswell) it runs 11.-11.4 at full boost 0,7 bar and 13ish at cruise, so i will have to sort the cruise fuelling at some stage.

I will keep it at the standard 0,7 bar for a while, its still very strong, and i want to have everything under control before I let it back on higher boost

Suspension:
Really like the new dampers, i was afraid they would be to much for the road, but actually they are better at handling bumps then my old less racey dampers. Its still on 350lbs springs, but I feel that the 425 that i also ordered could work as good, ill test that later, its a bit fiddly since i need to put the springs on the rear dampers to balance it, but i have them aswell. The only strange thing is that the rear right damper sounds weird, like a bicycle pump, trying to get some input from GAZ.

New brakes:
The new brake setup is working really well, nice pedal feel and good power modulation. The Ferrodo DS3.12 are pretty brutal when they get hot though, a bit to much bite for road tyres, lets hope it fits my wider track tyres well . However i might need to get some better rear pads to balance it up, im not sure what to get since i have to look at a mixed setups with different manufacturers.

So after fixing a few small issue like a loose boost pipe etc, hopefully i can continue to accumulate more driving and test things out a bit more. Not sure that I will have time to try any track or so this season, otherwise I will do that in the spring instead, im not stressing it. Im just glad that i can have fun on the twisty roads, which i have plenty of around here.


















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Cedric  



Joined: 27 Aug 2004
Posts: 2697
Location: Sweden

PostPosted: Sun Aug 18, 2024 2:57 am    Post subject: Reply with quote

Oh, and i get so many questions on my intercooler setup from guys on FB groups etc, so i will probably do a write up here in the near future
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morghen  



Joined: 21 Jan 2005
Posts: 8980
Location: Romania

PostPosted: Sun Aug 18, 2024 6:07 am    Post subject: Reply with quote

Really happy that you’re finally driving it and enjoying it.
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Mike9311  



Joined: 14 Dec 2004
Posts: 1760
Location: Chicago-ish

PostPosted: Mon Aug 19, 2024 1:56 am    Post subject: Reply with quote

morghen wrote:
Really happy that you’re finally driving it and enjoying it.


I second that feeling! I was wondering what was going on since I saw a lot more of the race car than this one on Instagram.

At a car show last night there was a GTO (pretty sure thats what it was) with so much space between the engine and radiator you could easily just stand in that space. I thought why do I choose the 924 to work on instead

Again, nice to see your car on the road again
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1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car
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Raize  



Joined: 18 Sep 2013
Posts: 255
Location: Scotland

PostPosted: Mon Aug 19, 2024 4:35 am    Post subject: Reply with quote

The intercooler is very nice and stealthy. Really nice looking car in general.
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Cedric  



Joined: 27 Aug 2004
Posts: 2697
Location: Sweden

PostPosted: Mon Aug 19, 2024 5:49 pm    Post subject: Reply with quote

Mike9311 wrote:
morghen wrote:
Really happy that you’re finally driving it and enjoying it.


I second that feeling! I was wondering what was going on since I saw a lot more of the race car than this one on Instagram.

At a car show last night there was a GTO (pretty sure thats what it was) with so much space between the engine and radiator you could easily just stand in that space. I thought why do I choose the 924 to work on instead

Again, nice to see your car on the road again


Hehe, when i see guys swapping head gaskets in the pits i also wonder why I do this, when its a friggin winter project and hundreds of $ (and swear words) for me . But it could be worse, its no 300ZX.
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Mike9311  



Joined: 14 Dec 2004
Posts: 1760
Location: Chicago-ish

PostPosted: Wed Dec 04, 2024 1:55 am    Post subject: Reply with quote

Cedric, can you give more detail on the brakes? Pretty sure I know they are Boxster / Cayman 2009-2012 or so calipers right?

I have been playing around with a project idea using 2017-2020 (+?) Cayman / Boxster Base calipers to see if they might drop a tiny bit of weight compared to the 968 Brembo Blacks on the car now. I just can't find any trustworthy info on the Caliper differences no matter how I look. 68 rotors should be 28mm which should match. While yours I believe were for slightly thinner rotors. I know I am wasting my time but you know me. Its a mental exercise when I am doing something else

Your setup looks awesome
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car
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Cedric  



Joined: 27 Aug 2004
Posts: 2697
Location: Sweden

PostPosted: Wed Dec 04, 2024 7:43 am    Post subject: Reply with quote

Mike9311 wrote:
Cedric, can you give more detail on the brakes? Pretty sure I know they are Boxster / Cayman 2009-2012 or so calipers right?

I have been playing around with a project idea using 2017-2020 (+?) Cayman / Boxster Base calipers to see if they might drop a tiny bit of weight compared to the 968 Brembo Blacks on the car now. I just can't find any trustworthy info on the Caliper differences no matter how I look. 68 rotors should be 28mm which should match. While yours I believe were for slightly thinner rotors. I know I am wasting my time but you know me. Its a mental exercise when I am doing something else

Your setup looks awesome


Boxster 986 non S calipers,.the ones with the same piston area as the std calipers. Its difficult to find details for sure, even harder nowadays when internet search results are a pile of poo. My Carrera discs are 24mm, i dont remember what the Boxster discs are, a few mm thicker than that.
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Mike9311  



Joined: 14 Dec 2004
Posts: 1760
Location: Chicago-ish

PostPosted: Thu Dec 05, 2024 1:10 am    Post subject: Reply with quote

Cedric wrote:
Mike9311 wrote:
Cedric, can you give more detail on the brakes? Pretty sure I know they are Boxster / Cayman 2009-2012 or so calipers right?

I have been playing around with a project idea using 2017-2020 (+?) Cayman / Boxster Base calipers to see if they might drop a tiny bit of weight compared to the 968 Brembo Blacks on the car now. I just can't find any trustworthy info on the Caliper differences no matter how I look. 68 rotors should be 28mm which should match. While yours I believe were for slightly thinner rotors. I know I am wasting my time but you know me. Its a mental exercise when I am doing something else

Your setup looks awesome


Boxster 986 non S calipers,.the ones with the same piston area as the std calipers. Its difficult to find details for sure, even harder nowadays when internet search results are a pile of poo. My Carrera discs are 24mm, i dont remember what the Boxster discs are, a few mm thicker than that.


"internet search results are a pile of poo" Totally true.

Thank you for all that info. From you I know its good
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car
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Cedric  



Joined: 27 Aug 2004
Posts: 2697
Location: Sweden

PostPosted: Thu Dec 05, 2024 6:12 am    Post subject: Reply with quote

Many have probably seen it on my IG or similar, but heres the pics to keep continuity in the thread.

As a fun little side project I made a bracket to stiffen up the master cylinder, it moves a little bit under really hard use, and why not try 3D printed aluminum at the same time to get a feeling on how it works for consumer use. It also fits well with the improved braking feel of the Boxster calipers.

So I did a quick and dirty scan, not great but without any prep, but good enough to design a few plastic printed iterations and the order the alu printed one. Sucessful so far with the garage testing, it greatly reduce the movement with really hard brake application, but since its winter i only tried it in the garage. The small flex that is still there is in the strut mount bracket, so quite diffcult to do anything about, the strut bar mounts arent designed for the twisting force.

Im really happy with the parts so far, so i will probably do more metal printing in the future, would be fun to do stainless aswell !

Made it in fusion, the scan is reduced to improve speed as Fusion dont like big meshes.







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Mike9311  



Joined: 14 Dec 2004
Posts: 1760
Location: Chicago-ish

PostPosted: Thu Dec 05, 2024 10:25 am    Post subject: Reply with quote

That is cool! I missed your IG
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car
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View user's profile Send private message
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