944Hybrids: 924/944/968 and 928 V8 Conversions
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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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New convert under way  - Page 18 Empty Trans mounts

Post  kevin924kevin Mon Feb 22, 2016 8:20 am

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New convert under way  - Page 18 Empty trans mount

Post  kevin924kevin Mon Feb 22, 2016 8:21 am

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New convert under way  - Page 18 Empty Trans mount

Post  kevin924kevin Mon Feb 22, 2016 8:22 am

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New convert under way  - Page 18 Empty Trans mount

Post  kevin924kevin Mon Feb 22, 2016 8:23 am

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New convert under way  - Page 18 Empty Trans mount

Post  kevin924kevin Mon Feb 22, 2016 8:26 am

Well this is how I will hang the Z06 trans. I was not happy with the look, very functional but not nice to look at. So I made some changes, which I will post pics of once they are complete. I think the changed units look much better but thats just me.
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New convert under way  - Page 18 Empty Brakes

Post  kevin924kevin Mon Feb 22, 2016 12:43 pm

Another piece of the puzzle arrived today. My new hydro boost unit showed up.
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New convert under way  - Page 18 Empty Trans mounts

Post  kevin924kevin Wed Feb 24, 2016 8:19 am

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Trans mounts ready for welding.
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New convert under way  - Page 18 Empty Trans mounts

Post  kevin924kevin Thu Mar 03, 2016 10:26 am

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Plates to mount the trans mount cross member. I have made the plates so they tie in the rear shock
mounts.
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New convert under way  - Page 18 Empty trans mount plates

Post  kevin924kevin Thu Mar 03, 2016 10:27 am

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New convert under way  - Page 18 Empty trans mount plates

Post  kevin924kevin Thu Mar 03, 2016 10:28 am

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I tried to make them fit as close as you can. The cross member will be welded to the plates and the trans will hang off of it with the new mounts. They should be ready today, they where setting up the laser unit to cut them yesterday.
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Post  sparkydog Fri Mar 04, 2016 1:51 pm

I'm really enjoying watching your progress! Just in case you haven't encountered this yet I wanted to warn you that when you start welding your various plates onto the sides of the 944's frame rails - the rails can be made of 2 or more layers of sheet metal and if you are using a MIG the outer layer of metal likes to pop/explode as you first apply an arc. I have photos of cuts I made into the frame rails just ahead of the upper shock mount area in case you want an idea of what the interior is like. The outer layer is a somewhat thinner skin and then there is thicker structural metal beneath it.
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New convert under way  - Page 18 Empty Re: New convert under way

Post  kevin924kevin Fri Mar 04, 2016 2:29 pm

Sparkydog please put the pics up. I would like to see the cross section so I know what is going to take place. Thank you for the heads up. Much appreciated.
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New convert under way  - Page 18 Empty Re: New convert under way

Post  sparkydog Sat Mar 05, 2016 8:25 am

Here is a shot of a slice directly through the upper shock mount bushings. This would be as if you were looking down onto the tops of the frame rails. The little stubby wings are the start of the upper shock mount "cups". But they are swapped left/right so the inboard surfaces are on the outsides.
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At least in this general section of the frame rails, Porsche had more of a C channel shape as the main structural component and then wrapped it up into a bigger, rectangular shape with thinner metal and then further layered the shock mount cup and the rear seatback bulkhead over the top of the tube.
It took me awhile and some swearing to to develop the ability to get a good weld bead into the deeper, stronger metal.

For more details you can go here
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and start at post 231. A few posts later there are a couple of shots from beneath looking up into the frame rail.
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New convert under way  - Page 18 Empty Re: New convert under way

Post  kevin924kevin Mon Mar 07, 2016 4:19 pm

Thank you for the pic and info
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Post  racertomtom Mon Mar 07, 2016 10:09 pm

kevin924kevin wrote:Thank you for the pic and info
Agreed! I had no idea the frame rails were made like that.

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New convert under way  - Page 18 Empty Re: New convert under way

Post  Slpr948 Mon Mar 07, 2016 11:21 pm

So what technique did you use to make a good full penetration weld into the outer and inner sheet metal?

Just a good clean surface, crank the heat (within reason)... and proper feed/move speed? Of course talking about MIG.

I was brainstorming, and you could probably take a cut off blade, and carefully slit through the first layer... then lay a bead into that channel, connecting the inner and outer layers, then grind it down and weld ontop of that. Even something more simplified like drilling small holes in the area youre planning on welding, and then filling that hole with weld... thus connecting the inner and outer pieces prior to laying big beads or stitch welds.


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New convert under way  - Page 18 Empty Re: New convert under way

Post  sparkydog Wed Mar 09, 2016 12:18 pm

Yeah the "technique" that I used was just to learn that I was going to get burned a lot by hot molten balls of metal blowing out and to just hang in there with feeding wire into the blast zone until it burned off the plating and then the bead would form properly. However it was frustrating because as you say the outer layer just gets burned through and you have to try and sneak the weld puddle over near it and let it wick.

The only other way is what you propose - cut into the outer skin to expose the heavier inner layer (and at the same time clean off the metal to get a good arc).

I believe what is happening is there is hot gas trapped between the outer and inner layer and it's got nowhere to go except back out into your face. So even after making a 1st pass bead if you go back and try to add a 2nd pass the instant you start welding into virgin outer layer you start popping hot metal again.

Post #254 on my link 1st picture has a good shot of the layers of metal in that portion of the frame. And post #261 last two pictures the arc around the tops of the little cup things are my best beads where I had one side new metal and the other side the 944's layered metal.
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New convert under way  - Page 18 Empty Re: New convert under way

Post  kevin924kevin Mon Mar 14, 2016 8:30 am

[You must be registered and logged in to see this image.] 930 CV adapter mounted[You must be registered and logged in to see this image.] 944 S2 axle stub that had ABS/ Machined down to accept 930 Adapter. I used my CV bolts i had and chased the thread all the way down, then cut. Worked out nice.


Last edited by kevin924kevin on Mon Mar 14, 2016 8:41 am; edited 2 times in total
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Post  kevin924kevin Mon Mar 14, 2016 8:31 am

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Trans mounts
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Post  kevin924kevin Mon Mar 14, 2016 8:33 am

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trans mount mock up
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Post  kevin924kevin Mon Mar 14, 2016 8:34 am

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Trans mounts
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Post  kevin924kevin Mon Mar 14, 2016 8:35 am

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trans mount.
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Post  kevin924kevin Mon Mar 14, 2016 8:46 am

I also worked on my HB unit. Cut the clevis off and threaded for my factory Porsche one. Worked out perfect. I will post that pic. I am still on the fence about the angle it needs to sit at. Do we need to modify the breather port on the drivers side valve cover, for more clearance for the HB unit?
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Post  kevin924kevin Mon Mar 14, 2016 11:25 am

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HB unit all ready
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Post  kevin924kevin Mon Mar 14, 2016 11:26 am

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