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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944 Firewall Reinforcement Plate

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New solution in the works...

Post by gt1scca on Fri Nov 13, 2009 12:41 pm

Reinforcement plate is in development...coming soon.

Watch for it early next week...
Products page
(bottom of page...)

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Re: 944 Firewall Reinforcement Plate

Post by robstah on Fri Nov 13, 2009 12:45 pm

Greg,

How does the reinforcement plate compare with the current plate for sale on the site? Is this another plate to use with the first plate, or is it an updated version of the first one?

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Re: 944 Firewall Reinforcement Plate

Post by gt1scca on Fri Nov 13, 2009 12:56 pm

This will be an update.

The flex problem has been discussed before, but not properly addressed. The clutch master has been the problem in the recent past, but the additional pedal pressure needed when converting to a manual setup with a power-assist master cylinder is taking its toll.

Also keep in mind what brake fluid and water (Glycol-ether brake fluids [Dot 3 & 4] are hygroscopic-i.e. absorb water) does to sheet metal after 20 years of exposure.

Time to correct it...

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Re: 944 Firewall Reinforcement Plate

Post by gt1scca on Mon Nov 16, 2009 3:34 am

I spent Saturday working on the '87 parts car...
It will be the "victim".

Brake booster removed, clutch master cylinder removed, and clutch and brake pedals removed for access to the firewall. I even disassembled the brake booster to see if the stock pushrod would be worth salvaging...nope. The clevis @ the pedal may be reused...that's about it.

From under the dash, you can see some things...
Like, the clutch pedal assist spring that needs to be removed for proper C5 slave operation...

[You must be registered and logged in to see this image.]

...the brake pedal retainer clips and pins...

[You must be registered and logged in to see this image.]

...and the fact that the firewall insulation has to come out completely for the firewall repair.
Neither the '87 nor the '86 Turbo car have any visible damage around the booster or clutch master (no rust, luckily), therefor the '87 is the mule.

While you're scratching your head wondering how to get the pedals out past the wiring harness and steering column, walk around to the driver's side front fender and remove the fuse panel. Move it to the side, remove the plastic cover from the clutch MC pushrod assembly, and say bye-bye to that big coil spring staring back at you...

[You must be registered and logged in to see this image.]

Remove the spring clip, and the support rod and spring come out in one piece...

[You must be registered and logged in to see this image.]

Here's the partially stripped firewall...
(FE Oxide / DOT 3 FREE...)

[You must be registered and logged in to see this image.]

You may be saying, "Was all that necessary?"
Yes, if you plan on repairing the firewall. Everything comes out, including the clutch master cylinder.

Stay tuned...

I have a template for the firewall plate, which will be a bolt-on solution.
The plate will reinforce areas around both the brake and clutch master cylinders, and there is enough adjustment on both pushrods to compensate for the thickness of the plate.

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Re: 944 Firewall Reinforcement Plate

Post by ghostcloak on Mon Nov 16, 2009 7:20 am

EXCELLENT WORK GREG! It doesn't look to be all that much of a pain really... Amirite?

When you said "there is enough adjustment on both pushrods to compensate for the thickness of the plate., are you referring to the stock brake pushrod or the custom Wilwood?
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Re: 944 Firewall Reinforcement Plate

Post by gt1scca on Mon Nov 16, 2009 9:10 am

Even a modified or custom brake pushrod will thread into the stock clevis @ the pedal, making the pushrod adjustable. The "stock" pushrod is junk, due in part to this...

[You must be registered and logged in to see this image.]

(...or did you mean RH pushrod?)
*The stock 944 pushrod clevis can be reused, that's about it.
Not everyone has the RH version.
Now, they won't need it.

Razz

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Re: 944 Firewall Reinforcement Plate

Post by gt1scca on Mon Nov 16, 2009 9:18 am

Tim,

What size was the plate you welded in?
You reinforced the clutch MC area only, right?
I have a template matched to the "flat" area of the firewall (including around the cereal bowl), and it is under 8" X 10", but it will be a 1/4" thick plate.

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Re: 944 Firewall Reinforcement Plate

Post by Dawgz83948 on Mon Nov 16, 2009 9:43 am

gt1scca wrote:Tim,

What size was the plate you welded in?
You reinforced the clutch MC area only, right?
I have a template matched to the "flat" area of the firewall (including around the cereal bowl), and it is under 8" X 10", but it will be a 1/4" thick plate.

1/16" Steel. I had it drilled for the 2 master cyl studs and welded directly to the firewall. I used to notice a good bit of flex before I did this and when it finally went I was stranded in Livermore. (1.5 hour tow to my mechanic) I need to double check the thickness but I'm 75% sure 1/16". Ohh anyway, there is absolutely NO flex at all when the clutch is pressed. But a word of warning, have someone inside the car with a spray bottle of water, because there will be fires. Also the guy who did the welding had a hard time NOT blowing holes through the firewall trying to get a good weld, but he finally got it.
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Re: 944 Firewall Reinforcement Plate

Post by gt1scca on Mon Nov 16, 2009 9:51 am

OK...

I was thinking about making it bolt-on, and use possibly seam sealer to keep out water, etc. If I can get 2 bolts close to the MC flange, the 1/4" plate should take most of the stress.

Whatcha think?

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Re: 944 Firewall Reinforcement Plate

Post by Dawgz83948 on Mon Nov 16, 2009 9:59 am

gt1scca wrote:OK...

I was thinking about making it bolt-on, and use possibly seam sealer to keep out water, etc. If I can get 2 bolts close to the MC flange, the 1/4" plate should take most of the stress.

Whatcha think?
Depends, I don't think bolt in (unless your talking about drilling the firewall and bolting it on the inside of the car) will work because it would not be transmitting the stresses through out the plate. You definately need to anchor the outer edges of the plate.
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Re: 944 Firewall Reinforcement Plate

Post by gt1scca on Mon Nov 16, 2009 10:31 am

Dawgz83948 wrote:...unless your talking about drilling the firewall and bolting it on the inside of the car.
OK.
There would be bolt holes drilled around the perimeter also, the cereal bowl existing holes, etc. Also, the clutch MC bolts would be incorporated.

Just trying to make it easy for the "do-it-yourselfers"...but it has to solve the flex problem (most importantly).

A weld-on version would definitely be best, but may not be feasible for some...

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Re: 944 Firewall Reinforcement Plate

Post by Dawgz83948 on Mon Nov 16, 2009 10:58 am

gt1scca wrote:
Dawgz83948 wrote:...unless your talking about drilling the firewall and bolting it on the inside of the car.
OK.
There would be bolt holes drilled around the perimeter also, the cereal bowl existing holes, etc. Also, the clutch MC bolts would be incorporated.

Just trying to make it easy for the "do-it-yourselfers"...but it has to solve the flex problem (most importantly).

A weld-on version would definitely be best, but may not be feasible for some...

It will work as long as the parimeter is bolted down.
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Re: 944 Firewall Reinforcement Plate

Post by Porch on Mon Nov 16, 2009 11:03 am

Why not make a piece that goes inside? It could be bolted on using the clutch m/c bolts, and would apply the pressure over a greater area (instead of the two little bolt areas)? I haven't looked under there in a while so it may not be possible.

Also, i had a problem with the clutch assist but i simply backed the assist off a little (loosened the adjustment nut). It works great and gives a slightly lighter pedal.
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Re: 944 Firewall Reinforcement Plate

Post by Dawgz83948 on Mon Nov 16, 2009 11:23 am

Porch wrote:Why not make a piece that goes inside? It could be bolted on using the clutch m/c bolts, and would apply the pressure over a greater area (instead of the two little bolt areas)? I haven't looked under there in a while so it may not be possible.

Also, i had a problem with the clutch assist but i simply backed the assist off a little (loosened the adjustment nut). It works great and gives a slightly lighter pedal.

There are reinforcement structures and such, too much to make a practical internal bracket.
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Re: 944 Firewall Reinforcement Plate

Post by gt1scca on Mon Nov 16, 2009 11:36 am

Take a look...

Pedal support interference inside...

[You must be registered and logged in to see this image.]

[You must be registered and logged in to see this image.]

The plate would be almost impossible to mount inside, unless the braces were taken out and reinstalled after the plate. WAY too involved. I thought the same thing at first...

Hey Chris, there is still tension on that spring, right? I was thinking that it may rattle, so am opting to remove it completely. The LTs still have an adequate pedal return after removal.

(Thanks Tim).

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Re: 944 Firewall Reinforcement Plate

Post by Porch on Mon Nov 16, 2009 1:45 pm

Ah, i see!
Still though, there has to be room for something! (I apologize in advance, i haven't been in that area of the car in a while)...but what about something like this?

[You must be registered and logged in to see this image.]

Yeah, there's still tension on the assist spring. I played around with it until it was where i liked it. I think it only took a few full turns of the adjustment nut to keep the pedal from sticking on the floor, and a few more just for the heck of it. At least on my car, the pedal was starting to get a little heavy when i backed it off too far. I know others have removed it too, though.

P.S.--don't be jealous of my amazing MS Paint skillz. Razz
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Re: 944 Firewall Reinforcement Plate

Post by ghostcloak on Thu Nov 19, 2009 7:23 am

Call me crazy, but what about a bolt on application and using JB Weld around the outide? Might not be as pretty or as strong, but shouldn't it be strong enough? That way you could get the plate to adhere to the existing firewall without the "mess" of having to undo a ton of wiring, worry about fires, etc...
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Re: 944 Firewall Reinforcement Plate

Post by 948 on Thu Nov 19, 2009 11:37 am

You could use this in between the panels [You must be registered and logged in to see this link.]
Drill holes thru both panels around the edge; the adhesive will mushroom into these holes and help with retention, then put rivets in.
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Re: 944 Firewall Reinforcement Plate

Post by gt1scca on Thu Nov 19, 2009 4:50 pm

Thanks Paul,

The plate template is being converted to a .dxf file for water and/or laser jet.
I'll post a pic when the file is complete...

What a Face

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Re: 944 Firewall Reinforcement Plate

Post by ghostcloak on Thu Nov 19, 2009 6:38 pm

Sweet jesus awesomeness
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Re: 944 Firewall Reinforcement Plate

Post by gt1scca on Fri Nov 20, 2009 7:35 pm

ghostcloak wrote:Sweet Jesus awesomeness
She's ready...

[You must be registered and logged in to see this image.]

Exported as .dxf, ready for the "freakin' laaaazzzzuuur beam"...
"Come 'n' listen to a story 'bout a man named SHH"...

BTW, "Greg" will be fine...

Razz


Last edited by gt1scca on Fri Nov 20, 2009 8:51 pm; edited 1 time in total

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Re: 944 Firewall Reinforcement Plate

Post by ghostcloak on Fri Nov 20, 2009 7:38 pm

Haha. Greg tells jokes for free... I love it Smile

Any idea when the first prototype/batch will be ready? This would make a KILLER x-mas gift to myself. Like seriously. It was so beautiful outside but I couldn't (well, I could but I don't want to make the flexing worse) drive the Porsche. Sad

Looks great Greg.
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In Proper Perspective...

Post by gt1scca on Fri Nov 20, 2009 8:33 pm

ghostcloak wrote:Haha. Greg tells jokes for free...

NOTE: This plate requires removal of the clutch master cylinder also...
gonna take a full day to install this one, but once it's done...it's done.

...Should be ready by Saint Nick-of-time. rendeer

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Re: 944 Firewall Reinforcement Plate

Post by ghostcloak on Sat Nov 21, 2009 1:22 am

Is there going to be a package deal with the new pushrod for the Wilwood mc and this plate? Also, will the OEM clutch mc pushrod have enough adjustment for the 1/4" plate?
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Re: 944 Firewall Reinforcement Plate

Post by gt1scca on Sat Nov 21, 2009 10:26 am

Yep.

After adjustment (clutch), there remains .25" of threaded pushrod. Not enough? Check out the size of that dinky pushrod...Tighten the locknut, and it's making room for the Fat Lady.

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The brake pushrod allows even more adjustment...

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Re: 944 Firewall Reinforcement Plate

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