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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LSA Supercharged 86 Porsche 944

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Re: LSA Supercharged 86 Porsche 944

Post  superman22x on Mon Jan 28, 2019 6:27 am

Awesome, glad the vibration is sorted out.  I'm going to attempt to make my own splines for the Porsche side of the coupling. I am making a dividing wheel for my lathe and I'm going to plunge a tool bit manually to make the splines.
Can you easily get to where those bolts are with an Allen wrench when it is installed in the car?
For the axles, I need different sizes anyway since my car is an early one, my axles are 16.25".  My driver side will need to be about 15.5" for this trans.  I'm going to try and make those myself as well from 4340 with a dividing head on the mill.

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Re: LSA Supercharged 86 Porsche 944

Post  LSA_944 on Tue Jan 29, 2019 6:45 am

I tried to get the coupler splines cut professionally but nobody could do it for me and my fabrication shop at work doesn't have the proper CNC bits (yet) to cut them. Spline cutting tools/bits can be extremely costly yet have very little return on investment. Especially our splines which seem to be unique to porsche and some VWs. From my research, I think the porsche splines are 23 spline, 24.2 mm Diameter, involute splines and the trans is 23 spline, 25.4 mm Diameter, involute splines. I wanted to make my coupler repairable so I simply made it so a clutch disc spline can bolt right up to it in the even I shred them. That part of the coupler is my weakest point (but still extremely strong). The front screws that hold the coupler in place are in the same location as the groove cut into the torque shaft. They are accessible through the little hole in the torque tube as with the original coupler. The bolts into the rear of my coupler are through bolts that thread into the otherside of the coupler. This bolt has a steel sleeve on the inside portion of the bolt that stops against the tip of the input shaft of the trans. This allows trans removals to be far easier. Good luck with your install and wish you the best at attempting it all DIY. Let me know how you plan tackle the shifter connection to the trans. As you can see in my pics, I first attempted to route everything through the hole in the trans housing by removing material to enlarge it. Ultimately, this was unnecessary for my final install. Just keep in mind that you may have to modify the trans casing a bit depending on how you design your shift connections and it is much easier to do this with the trans out of the car (one would this to be rather obvious but I tested the theory anyway and it is way easier with it out). Let me know if you have any questions or need some help.

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Re: LSA Supercharged 86 Porsche 944

Post  superman22x on Tue Jan 29, 2019 7:50 pm

I'm thinking a TCMT 2152 insert will give me the correct profile for the splines.  This is what I have seen used by some other to make axles as well.  It's not a true involute profile, but should be close enough.  

For the shifter mechanism, this is what I have so far.  I just fit it together with set screws to test it.  But I don't see any problems making it work.  I will just weld up the joints to make it fit better.  I need to trim the aluminum block that mounts to the shift rod into the transmission.  

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superman22x

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Re: LSA Supercharged 86 Porsche 944

Post  superman22x on Tue Jan 29, 2019 8:00 pm

This is the thread with the cutter I was referring too.  He uses TGP321 inserts.  Nearly the same as the TCMT2152 inserts I have, just slightly smaller nose radius.  But for our application, the larger nose radius will work well I think.

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superman22x

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Re: LSA Supercharged 86 Porsche 944

Post  superman22x on Tue Feb 12, 2019 9:16 am

I have made my torque tube coupling now, or nearly complete. I tried cutting internal splines in a chunk of scrap aluminum. My home-made tool didn't quite work, it didn't provide enough support for the TCMT insert. So it broke the insert too easily. The profile was looking good up until that point. I may try again in the future. For now however, I made something similar to yours. I coupled a 944 torque tube coupler to an audi clutch hub. The 944 coupling lightly press fits inside of my machined part. I plan to use 3 5/16 dowel pins to constrain them together. I may weld as well, but the dowel pins have 16,000 lbs double shear strength each, so I may skip the welding. That's good for about 2,400 ft-lbs of torque where they are on the shaft diameter (OD of the Porsche torque tube coupler). In comparison, the torque tube shaft is good for around 880 ft-lbs in a perfect world (1" shaft, assumed tensile strength of 108,000psi).

Anyway, here's what it looks like:

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superman22x

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Re: LSA Supercharged 86 Porsche 944

Post  LSA_944 on Tue Feb 19, 2019 9:57 pm

Looks like you are nearing completion. How does the shifts feel using the 944 shift bar? I went with shift cables due to the adjust-ability with them but I like how clean yours looks reusing the original shift bar. I may go that route in the future if I run into any issues with the cables. Did you add anything to the coupler to prevent the torque shaft from walking out of the pilot bearing?

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Re: LSA Supercharged 86 Porsche 944

Post  superman22x Yesterday at 10:48 am

I didn't think about torque tube shaft movement. I thought those bolts were only to remove slop from the spline and to keep just the coupling from moving. I only put the one bolt in.

The shifter needs some more work, it currently bumps into the frame. I need to tweak it a little. And I'm putting in a better Ujoint.

What did you do for mounting? Did you reuse the late trans mount?

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Re: LSA Supercharged 86 Porsche 944

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