HOW TO DO AN ADVANCED SEARCH.

Mon Jul 08, 2013 3:56 pm by Admin


For the benefit of 944Hybrids users there are two search functions available for you to use.
The purpose of this sticky is to explain the "Advanced Search" function because it is much more powerful and is the best choice when researching information.

When you log on to the site a list of options is shown in a line at the top of the page. One option is labelled "Search", use this option (NOT the search box lower down on the right).

After you click on the upper search option, a drop down box appears. At the bottom of this box is a radio button marked "Advanced …

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Frosty's 83 944 LM7 Project

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Frosty's 83 944 LM7 Project

Post  frostyballs on Sun Jun 22, 2014 10:23 am

Hello all,

I have an 83 944 that I'm putting an LM7 into.  The project is coming along; I'm about 6 months into it.  Finding time to work on the car is hit and miss, but I am enjoying it.  The interior is stripped, wiring is labeled and out, the engine and transaxle are pulled, the interior is getting close to being ready for paint, and the LM7 rebuild is well underway.  Now that you're caught up, more detailed posts to follow.

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frostyballs

Posts : 25
Join date : 2014-06-16
Location : Vass, NC

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Getting the Shop Together

Post  frostyballs on Sun Jun 22, 2014 2:19 pm

Haven't made much progress on the car this weekend, but dramatically improved the work space.  I couldn't take all the parts piled on the ground, so I pieced together a second work bench and some shelves with wood that was laying around.  I also picked up a solvent tank to start cleaning things up, since I'm getting close to putting things together, rather than taking them apart.

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frostyballs

Posts : 25
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Location : Vass, NC

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Re: Frosty's 83 944 LM7 Project

Post  99sierra4x4 on Mon Jun 23, 2014 8:39 pm

Looking good!

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Home Again

Post  frostyballs on Thu Oct 09, 2014 7:33 am

Finally home after a long business trip and eager to get into the shop. In the last couple weeks I've gotten the LM7 block and heads cleaned up. I can't see any unusual wear or damage, everything is as expected. I'm going to try and take them up to a local guy in Carthage who does (so I was told) quality engine machining. I'm also pulling off the suspension and brakes from the car (that's about all that's left on the body) and will be removing the torque tube... which is still hanging out underneath. I'm thinking I'll take a closer look at the transaxle and torque tube, maybe see what kind of condition it's in and look around for some recommendations on what kind of torque/horsepower it can handle (it is a non-turbo model). At any rate, some new pics are soon to follow.

I've started helping out in a local mechanic shop, just for my own learning and experience. The owner runs a late model race car on local dirt tracks around the area. My wife and I went down and watched one on Saturday. I've never seen so much horsepower and so many "NC natives".... pretty good time though. Those guys rip around that track. Maybe in a few years when my car comes together... if I'm not broke from taking care of our new baby....

frostyballs

Posts : 25
Join date : 2014-06-16
Location : Vass, NC

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Wheels!

Post  frostyballs on Fri Nov 14, 2014 3:20 pm

I got the engine dropped off at Ted's in Carthage. I had a good chat with him too. Apparently he's known my mechanic friend for 30 years or so... seems its a pretty tightly knit community around here. He's going to magnaflux, hone, and deck the block. Port and polish the heads. I also got ahold of an LS1 intake, cam shaft, and valve springs.

I ordered the basic install kit from TPC and found a two piece C5 bell housing. So... Got a few other bits and pieces to source, mainly dealing with the truck LS accessories and getting ahold of some decent seats. All in all, things are coming along.

I picked up some wheels from a Subaru impreza, as well as had some custom hub adapters made for proper lug pattern and  wheel spacing. I think they look pretty sharp and I can't wait to get them on, but I had to mock it up (roughly) for my own morale...  Soon it will all be coming together!

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frostyballs

Posts : 25
Join date : 2014-06-16
Location : Vass, NC

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Seats and Rebuilds

Post  frostyballs on Tue Dec 23, 2014 6:18 am

Good news! Ted has finished up with the heads, and asked me to drop off the new valve seals.... this prompted me to try and remember what year of engine I have, in order to buy the parts. Unfortunately, I couldn't. I was thinking 01 or 02... The casting number is 02 to 04, and it has multilayer head gaskets (02+), and I believe they went to drive by wire in 04. My guess is 02, and that's what I went with when ordering all the rebuild parts. Full gasket set, rings, rod-cam-main bearings, oil pump, and timing set. Hopefully the block will be ready to go come mid January.

The second bit of good news... I had a major find on Craig's List. Two corbeau seats, with camlock harnesses, and camaro sliders... All for $500. Never used, beautiful condition, the poor guy crashed his 75 camaro before he could put them in. It looks like they'll mount pretty easily in the car, with some minor modification.

Updated pics soon. And a question for those with experience, which LS engine accessory layout is preferred in the 944, corvette layout or alternator below? Thanks.

frostyballs

Posts : 25
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Location : Vass, NC

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Re: Frosty's 83 944 LM7 Project

Post  frostyballs on Wed Dec 31, 2014 1:31 pm

Started noticing a little bit of rust forming on a couple spots where the interior had been wire brushed... guess its time to put a little paint on... if only to keep the rust off. After a bit of dileberation, I've decided to with a gloss black exterior, white interior, rubber undersealed floor pans, and a blue cage. Here's a couple pics as promised... if any one is actually reading this Wink

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frostyballs

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Location : Vass, NC

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Re: Frosty's 83 944 LM7 Project

Post  majormojo on Wed Dec 31, 2014 4:25 pm

Nice find on the seats!
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Short Block

Post  frostyballs on Sun Mar 01, 2015 3:32 pm

More progress, slow and steady... getting a few hours here and there.

I dropped the rear suspension in order to pull the torque tube out.  It was fairly uneventful, just a matter of locating all of the mounting bolts and finding enough pieces of wood to support it once it was loose.  The torque tube came out easily after that.  I considered rebuilding the bearings, but they feel very good.  I took the angle grinder with a wire brush to the tube, then painted it up.

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I also picked up my block from the machine shop.  I had the cylinders honed, the block decked and align honed, and the heads rebuilt.  The shop put the cam bearings and the freeze plugs in.  Since I got it back in the garage, I've gotten a bit of time to work on it.  I painted the block, measured the main bearing clearance, and installed the crank.  I cleaned up the stock pistons and rods, installed new rings, measured the rod bearing clearances, and installed the rods and pistons.  The short block is now ready for the cam and heads.

The main and rod bearing clearances are 0.018, the ring gaps are 0.013 for the top ring, and 0.20 for the 2nd ring.  The main and rod bolts were reused, since this is the first time the engine has been apart and the only modification will be the ls1 cam, valve springs, and intake.

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Almost forgot, I also picked up a 944 turbo with a twisted tub.  The car isn't of much value, but the parts on it will give me just about everything else I need.  Transaxle, brakes, windshield, front bumper, right rear quarter, and... we'll see what else.  I'm going to part out the rest, which is in pretty good shape.

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frostyballs

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Location : Vass, NC

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Front End

Post  frostyballs on Tue Mar 24, 2015 6:43 pm

Had a few hours on Saturday, so I pulled the nose and front quarters off the good tub in preparation for placing the pieces from the donor car.

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frostyballs

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Re: Frosty's 83 944 LM7 Project

Post  wingdog on Wed Mar 25, 2015 9:29 am

Looks like its gonna be awsome. My 5.3 completly stock really scoots in my car, I'm sure with the cam it'll move nicely.

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Hydraulic Lifters?

Post  frostyballs on Mon Apr 06, 2015 11:05 am

Having fun getting the engine put together, it's mocked up here.  It's going to be awesome...

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I've run into a speed bump with the engine rebuild.  I started putting together the top end, the lifters looked good, I put the lifter trays in, used copper gasket sealer on the head gaskets and torqued the heads down using TTY head bolts.  I suppose I should have inspected the push rods and rockers before I torqued the heads down.  I can see that one rocker from each head is showing unusual wear.  The wear is between the push rod tip and the rocker cup, as if oil wasn't making it up between the surfaces, or the hydraulic lifter wasn't keeping the appropriate pressure between the parts.

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The cup on the left looks normal, but the one on the right shows an obvious failure.  The interesting thing is that its only two out of the 16 rod to rocker cups shows this wear, with the corresponding tips looking similar.

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So... I'm learning a lot as this goes along, having never done a complete rebuild.  At this point it looks to me as if two of the hydraulic lifters had started to fail and that's what led to the engine being replaced by the previous owner.  I'm open to input and I'm going to ask some more knowledgeable friends if they think this is the case.

At this point I'm looking at pulling the heads back off and putting in new lifters, push rods, and rockers.

frostyballs

Posts : 25
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Location : Vass, NC

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Front End and Alignment

Post  frostyballs on Sat Apr 18, 2015 7:09 pm

I've had a chance to tear into the donor car, I pulled the front quarters and the bumper today.  I placed them on the car I'm building, but haven't attached anything yet.  The panels need to be cleaned up a bit first.  I also roughly checked the alignment on the car, because of the damage in the right rear quarter.  I have measured the bottom of the unibody, but haven't been able to find any distortion in the frame.  When I checked the alignment, the left rear seems nearly straight, just a hair of toe in, but the right rear has about 3/8 of an inch toe in at the tire (front outer edge to rear outer edge).  I'm not sure if this is within the adjustment range of the trailing arm, but I'm aiming to find out before I invest too much more time.  I also removed the old windshield... it was a little rough.

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frostyballs

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Location : Vass, NC

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Nose Panel

Post  frostyballs on Sun Apr 19, 2015 2:26 pm

I removed the nose panel off the car by drilling the spot welds, and man handling it a little.  The 86 turbo panel fits nicely, after creating some new attachment points.  I mocked everything up to check the fit and it looks good.  I also noticed that the string alignment method I'd done yesterday wasn't accurate due to the strings being wider at the front of the car.  After getting things close to parallel, the actual toe in is 1/16 of an inch between front and back of the rim for the left rear wheel, and close to 1/8 for the right wheel.  This makes me feel quite a bit better, the inverse tangent of 1/8 inch over 18 inches (the wheel width) gives an angle of about 23 minutes, which I believe is within the adjustment range.

Today was a win on two accounts, looks like the frame is probably good, and the front end is probably a bit lighter from all the new holes...

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frostyballs

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Back to the Engine...

Post  frostyballs on Sun Jun 07, 2015 6:13 pm

I finally got my stuff together and purchased the necessary parts for my V8 build (after finding out that my 5.3 had been removed and sold due to hydraulic lifter failure). I've now got the short block assembled with ARP main studs and rod bolts.  I decided to stick with the original dished pistons, due to the block being decked and the compression ration already being up around 10:1.  I installed a trick flow 0.575/0.575, 286/282, 112 LSA, new timing set, new hydraulic lifters, and am currently swapping out the valve springs with COMP CAMS LS1 RPM valvetrain upgrade kit.

I'm also removing the 86 turbo 4 piston black brake calipers, rotors, and spindles to place on the 83 project car.  I've entered a world of hurt trying to break a few of those old stubborn suspension bolts free...

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frostyballs

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Location : Vass, NC

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Engine and Suspension Work

Post  frostyballs on Fri Jun 19, 2015 6:37 am

I figure I'm over due for an update.  My second attempt at rebuilding the 5.3 has gone better than the first.  I'm waiting on a couple new sensors from Summit, then I'll be fitting it in the car.  I've spent the last couple days swapping over the front hub, rotor, and calipers from the 86 turbo donor car to my 83 build.  The right side is all together, and the left will be finished today.  I've decided to keep the early steel lower control arms, due to the lower cup bushing being replaceable, unlike the later aluminum arm.

Here's the right front, with the little black 4 piston calipers.

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Putting the bottom end together.

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Putting the cam in.

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Left side lower control arm dis-assembly.

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That's all for now.  Thanks for checking out the progress.

frostyballs

Posts : 25
Join date : 2014-06-16
Location : Vass, NC

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Sale of Project

Post  frostyballs on Mon Jun 22, 2015 6:56 am

Due to medical difficulties I'm considering selling the project. It will include both cars and the TPC conversion kit. I will be keeping the v8 and taking care of it separately. Please let me know if you have any interest and I will gladly provide any details. Thanks.

Mike
253-232-6155
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frostyballs

Posts : 25
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Location : Vass, NC

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TPC mounts and spacers

Post  frostyballs on Fri Jun 26, 2015 7:21 am

I am continuing to work on the car, despite listing it.  I'm on the fence, but feel like I might be able to keep going with it.  I've been working on the motor mounts and cross member spacers, courtesy of TPC. While removing the cross member for the first time, one of the larger M12 bolts broke off deep in the hole, it was rusted in pretty good. I've drilled out the hole with a left handed bit, but nothing came loose. My plan is the drill it back to stock size and then attempting to tap the hole.

I'm also finishing up pulling the turbo trans from my donor car.  The donor has a lot more corrosion than the build car, and it has been a serious PITA to get the transmission loose. My desire to have the tougher hear box keeps me going.

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I'm pretty excited to test fit the 5.3... Just waiting on the new tap and die set.

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A bit more progress...

Post  frostyballs on Sat Jun 27, 2015 3:35 pm

Today I mocked up the seats to weld the brackets in place some time in the future.  I also test fit the new engine on the TPC motor mounts, and painted a bit of the engine compartment.  Getting the spacers between the rails and the cross member wasn't fun.  I drilled and re-tapped the hole with the broken bolt and... success.  Everything is solid now.  One last thing, finally liberated the turbo trans from my donor car... a lot of corroded bolts... drilled and angle grinned the damn thing out.

It's amazing how much free time I have, since I'm not working right now.  I guess the car is filling the void for now, keeping me busy, and keeping my mind from wandering too far off course.  There isn't many other things as soothing and satisfying as spending a day in the shop.  Don't tell my wife... but I guess you wouldn't have too, I think she's already got that one figured out.

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frostyballs

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Re: Frosty's 83 944 LM7 Project

Post  Lemming on Sat Jun 27, 2015 4:58 pm

Nice, keep going!
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Details...

Post  frostyballs on Mon Jun 29, 2015 3:56 pm

Getting into the weeds now.  I've got the new flywheel on the engine and I'm working on getting the turbo trans cleaned up.  I set the intake manifold on too, just to enjoy the view for a bit.  I'm digging into the braking system as well.  

I have the bias valve from the turbo car, to go with the little black calipers, but I'm not aware of the differences between the porsche master cylinder and the suggested wilwood 260-8794.  I'm considering fabricating my own plate to mount the factory master cylinder without the brake booster, but in the same location.  It seems like the diameter is about the same as the wilwood model, and the brake lines don't connect on the bottom, eliminating some of the challenges with heating by the exhaust manifold.  It feels like I must be missing something, why don't people run it this way?

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frostyballs

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Clutch, Torque Tube, MS Plate

Post  frostyballs on Sat Jul 04, 2015 8:19 am

Here's the latest updates... The clutch and torque tube are on.  The splines on the drive shaft had some trouble going into the splines on the clutch disc (from TPC).  Fortunately, after several hours of struggling, I noticed that the engine mounts weren't sitting symmetrically.  The left mount was all the way to the rear of it's adjustment range and was causing the entire engine to sit at an angle in the engine bay.  After loosening, prying, and cursing a little, everything was squared up and the shaft went into the disc without complication.

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I'm also having my father fabricate a master cylinder to firewall adapter plate out of 1/4 inch aluminum.  I'll be reusing the factory master cylinder with the 86 turbo biasing valve to accommodate the 4 piston calipers.

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frostyballs

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Fabrication and Shipping

Post  frostyballs on Fri Jul 10, 2015 6:14 am

I'm going to try and take the car with me when I move back to the west coast... unless a reasonable offer comes around.  With this in mind, I've taken to trying to prepare the car for shipping by getting the hatch, doors, hood, and glass back on it.  I've got a new windshield going on it on Monday, for a bit less than $300, and I managed to jump the window motors with an extra battery I had lying around in order to get them closed.

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Also making progress on several other fronts.  I received the adapter plate which my dad made for the brake master cylinder.  It looks like it's going to be a good fit, and should cant the MS away from the driver's side head, to give a little more room.  Now I need to track down some hardware to get everything bolted up.

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I ordered a piece of 1/2 inch aluminum stock to make an adapter plate, which will allow the 86 turbo transmission with intercooler to go on the 83 NA mounting points.  I had to order a few new cobalt drill bits in order to get the holes the right size.

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The water pump spacing kit I ordered arrived yesterday and looks like it will be a good fit.  I still need to pickup an F-body water pump and belt tensioner.

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Last, I mounted the Kwik alternator bracket, and it looks to be of reasonable quality.  Testing the hood clearance the setup should work well, the alternator sitting slightly lower than the ls1 intake throttle body, which just clears the hood.

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frostyballs

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More Progress

Post  frostyballs on Mon Jul 13, 2015 3:09 pm

Made some minor progress... ordered some 1/2 inch aluminum and made an adapter plate to mount the turbo trans onto the early 83 mounting points.  I drilled and tapped the bar stock to bolt the transmission straight onto it.

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I also got a new windshield installed today.  Safelite was quick and painless, and it only cost $270.  It's nice to see the car coming together.

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The brake master cylinder test fit went pretty well, looks like the adapter plate is going to work.  Now I have to drill the pedal arm in order to line things up and increase the leverage.

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frostyballs

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Transmission Plate

Post  frostyballs on Wed Jul 15, 2015 7:24 pm

Got the transmission bolted back in today, but not yet attached to the torque tube, and removed most of the spare tire well. I elected to go with the early transmission mounts, the passenger side only being attached by two bolts. This seemed more prudent than fabing the adapter plate that I was working on. I imagine that the mounts will be strong enough, as the turbo trans mount is only two fairly small, maybe 8 mm bolts. I also got an f-body water pump, belt tensioner, and MAF sensor in the mail, along with a painless performance wiring harness. All in all, it looks like the next few days should be fun Smile

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Re: Frosty's 83 944 LM7 Project

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