914-SHO Project Thread

[Shoaz]

No, that doesn't address the issue with that bracket, which is that there's a torque on the bracket from the weight of the engine that will crack the bracket down the middle (between the four bolts that attach it to the block) if it isn't reinforced with something. In the OEM application the a/c compressor takes the load, but when it's gone the load can be taken up by a flat plate bolted through where the a/c compressor normally attaches, the top of which you've used for the alternator support.

Like this:

 

[3d914]

I follow. I'll have to work something up that doesn't interfere with my motor mounts. I suspect 1/4" plate would be sufficient. Keep you posted with what I come up with.

Thanks.

 

[3d914]

Took a break and went back to body work on the 914. I have a 6" x 8" section of the longitudinal to patch on one side. I'm basically replacing the jack point on this side as I never use them and they just attract rust.

The small triangular-looking piece with welds is to finish off the first of two overlapping layers of metal.

 

[3d914]

Then I needed to go back and fill the holes left from drilling out spot welds. Since my welder doesn't have much control (Low, Off, High) I needed a way to fill-in the holes.

I came up with a unique method. I found some steel nails with heads very near the diameter of the holes. I then place the nail pointing out with the head in the hole and use a magnet to suspend the nail in place. I then can weld around the base of the nail and it fills in nicely - then just grind off the nail that sticking out.

Seems to work pretty good.

 

[3d914]

OK, now the patch for the inner piece. I wanted a good fit, so I'm doing a butt-weld, without clamps, using a wire core welder - they said it couldn't be done.

Little bit of splatter, but I'm pleased with the results.

 

[3d914]

I had to fix a blow-out in the lower-left. It's a tight fit against the outer long, and I can't trim it back farther because the inner has a large stamped hole to the left. It patched pretty good though.

Now the grindings done and ready to fit & bend the outer long patch.

 

[3d914]

Working like crazy today. Seven hours in so far and I have the outer long bent into shape, fitted and ready to weld in.

Had to at least tack it in. I'll save the rest for tomorrow.

 

[3d914]

Finished up the weld and grinding. Tried out one of the 3M abrasive pads today. I like the finish it provides, and it doesn't heat up the metal the way the grinder wheel does. So I've been using both, one on the pneumatic die-grinder the other on my electric grinder. I use the grinding wheel to get the welds down to the metal, then use the abrasive pad to clean it up.

The few spots remaining to the left are outside the butt-weld. I was just filling in low spots on the adjacent piece - no end to it though.

 

[3d914]

Took a break today from my car and worked on my son's 914. Got the engine, clutch & tranny assembled. All the sheet metal for engine cooling goes on next. It's quite a bit smaller than the SHO motor. Lighter too!
Don't let its small size fool ya. Engine builders can get 200+ HP from these normally aspirated. Unfortunately the cost is up there too.

 

[3d914]

With the outer long done, I went back to finish up the longitudinal shelf section under the battery tray. I had this welded up, but didn't do the finish work. Now with a working compressor again I was able to get this cleaned up.

This is what it looked like with the rusted outer long cut out. You can see the inner long underneath.

Now the outer long is on. I still have to replace a section where the battery tray mounted, but I've got some surface rust to deal with and decide what needs to be cut out.

I also trimmed off the 2" shelf at the front of the engine bay. This gives me some extra clearance for accessing front of SHO motor.

 

[intimdatr]

ive the EXACT same rust repair you have. Batteries and foliage kills that area.

Looking good!

 

[3d914]

Filled in all the holes on the front of right inner suspension console. Got a little too aggressive drilling out spot welds when I removed the shelf (see post on previous page). I used my nail head technique to keep from blowing through. It saves me a lot of time, and provides good results.

 

[Shovert]

Nice looking work. Excellant. Maurice

 

[3d914]

Completed the remaining holes that needed welding. Thought I'd share the nail-head technique I use since my welder is limited to two temps - Low & High.

I found some steel nails with small heads (approx 1/4" dia), so I just place them in the holes and use some small welding magnets I found at HF to hold them.

The first weld secures the nails so I can remove the magnets . . .

I continue to weld around the nail head . . .

Then it's just a matter of grinding off the nail and grinding down the weld.

Repeat as needed.

 

[intimdatr]

Wish id know that trick some time ago. Slick!

 

[3d914]

Continue work on the right side of the engine bay. I cleaned up the surface rust near the battery box area and cut out the bad parts. Got my pattern made, but need to cut it out.

I did get the remaining piece for the hole in the lower-left recut, fit an partially welded. I'll get more pics when both pieces are done - this will wrap up the right side.

 

[Phoenix]

Keep up the good work.

Im pretty much knee deep myself too in my shogun build , and its alot of work - this build is very similar to mine. I love it.

 

[3d914]

Phoenix, got a link to a progress thread? I'd like to check it out.

 

[3d914]

Well finally took some time to build my special DIS cables, weld on a couple of mounting plates, and mount the DIS. And yes, I did use the required heat sink compound.

 

[Off Road SHO]

Did you remember the foil and drain wire?