build issues continue

Hey guys. I keep getting stuck. Fix one and another pops up.

My firewall had too much flex so I added the firewall plat which works great. now the clutch has failed again. Was using the Porsche master standard self adjusting slave. The plate reduces the stock travel by 1/8.

I switched to a willwood 13/16" master. After a bunch of hacking and tweaking it is in but the eyelet for the willwood is .640 in diameter. The Porsche pedal has a .460 pin. WTF


Then I keep having steering rack to header clearance issues. I went with Kents headers rather than try to mod the hookers. Has anybody had the header hit the rack linkage? How much clearance do you have. I dented it as much as I could and it still wont clear.

Thanks!

Thanks Kent for all the tips!
The 924 is different than the 944 so my issues are unique.
The quicktime bellhousing is slightly deeper so I need to shim the clutch slave cylinder.

I had the exact same problem you had with the flex and then adding a plate to stop the flex except my plate was more of a brace that went from the clutch master to the shock tower stopping the flex.

After many problems that all ended with fluid inside the car from clutch master failure, I tore down the clutch master and found that it had worn on one side of the piston.  Upon closer inspection I found that with the brace and in your case the plate, all of this CHANGED the angle of your mount.  The stamp in the firewall allows this clutch master to be at just the right angle.  If the angle is changed, then the clutch master piston will rub until failure along with a overly stiff clutch pedal.  

I fixed the angle when I mounted the new one and wow.........all the problems are now GONE.  Clutch is smooth and much easier to depress and no more loss of fluid.  This is my experience, I hope it helps in your troubleshooting.