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Discussion Starter #21
After a few calls/e-mails to Porsche, and Erik, along with some crude measurements,
I think I've found my fittings! I've ordered a 12mm x 1.25 AN adapter for
the slave which will connect the braided hose to the hydraulic master.

It will be a -4AN which is more than enough; I just hope everything assembles
as planned.

Since I haven't updated this thread in a while, here are some pictures of the
build progress. Once the clutch gets connected, and the cold snow disappears,
I'll finally have a go-karting test video to share.

My first attempt at flux core welding. Not perfect, but not bad for a couple of hours practice. This system will likely be upgraded next season anyway.


Painted the axles, and reluctor to prevent rust. It looks pretty good, and will match the colour of the car.


This is how the G96 connects via cable shift. Slight modifications required by grinding out the ball posts, and inserting the threaded links.


For those using cable throttle, here's a cost effective, and high quality solution. Teleflex, Marine throttle cable. Smooth, and durable. I had to
modify the accelerator pedal with a metal tab, but it's a done deal. Just
needs some paint.
 

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Discussion Starter #22
It turns out, the thread pitch for the slave hydraulic line is not 1.25.
So much for my crude measurements! Thread pitch gauge is tough
to read while standing on your head, and getting around all of the
obstacles in the GTM engine bay.

Eric wrote to tell me he found an adapter, and it's enroute via mail.
Hopefully it arrives this week. I'll update the size of the fitting once
it's confirmed for those using the G96 and/or similar slave.
 

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Discussion Starter #23
Today was one of those, "HELL YES" to "#@#$ NO" days.

The parts from Erik arrived today, so I thought the clutch line could be
installed, and bled. It turns out, the fitting is proper for the clutch side,
but the hose end is -3 AN.

I had already run -4 AN Teflon braid with -4 fittings so you can imagine
my disappointment when finding out the mismatch. This is no blame to
Erik however, he didn't know I ran the bigger fitting. Stupid me didn't
even bother to mention the size.

Thank you Erik for coming through again! I've ordered a -4AN to 12mm x 1.0
metric adapter to complete the link.

For those using the G96.00 transaxle with slave PN# 997.116.237.04, this is
what I recommend for materials:

12 mm x 1.0 metric to AN adapter (-4 AN). Russell# 670420
10 feet of PowerFlex, Teflon braid hose. Russell#632560
90 degree PowerFlex Endura Hose end, Russell#620441
Straight PowerFlex Endura Hose end, Russell#620141
3/8" NPT to - 4AN Adapter Fitting (Master end, NC24), Russell#640301

This will get you hooked up, first shot with no headaches. -4 AN is more
readily stocked around here, but there are options for -3 AN if you can find
a supplier.

I truly hope this saves someone some time, and money. I'll be listing a bunch
of parts for resale that I no longer need. Dealzzzzzzzzzz a'comin'!
 

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Discussion Starter #24
Installed the clutch line today! I broke down and bought some temporary fittings as the -4AN to 12mm x 1.0 fitting is backordered. Tomorrow I'll bleed the system, and might be able to roll around a bit (if the weather is warm)! We are still getting 0-5 degree C temps. :S

Also spent time looming wires, and cleaning off a bit of dust (need to get "Kempo-clean!). I'd like to get some video of the startup for sharing. If nothing else, I'll put the car on jack stands to run the motor up to operating temps, and run through the gears. It will be nice to hear it running again since before Christmas.





 

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Silly question

Keep in mind I'm not a mechanic, but looking at your brake master cylinders, you have the lines coming out the top, instead of the front. I thought the lines went out the front, and the top outlets were for bleeding.

Is there a reason you plumbed it the way you did?
 

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Discussion Starter #26 (Edited)
Taz, it's not silly at all.

The kit car was purchased used, with the master cylinders already plumbed
(along with the suspension, and a few other things).

I didn't think anything of it; I figured it was routed that way due to tight
spacing as most things in the GTM.

The bleeder must be the highest point in any system (cooling, hydraulic, etc.),
so the loops being higher than the bleeder screw will cause air to get trapped
at the highest point, and never bleed out.

Now that you mention it, I'm thinking I have a bit of work ahead of me. Didn't
even notice all this time, but I'm betting it would have hit me in the face when
I bled the system. :001_huh:
 

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Discussion Starter #27
Some finishing touches for today. Seat belts, trimmed some electrical wiring,
connected a couple of gauges, and put the car on jack stands.

Tomorrow's job: bleed the clutch, brakes, and go for a spin. I guess I'll be
rerouting some steel lines too! Thanks Taz for the heads-up.



Don't mind the direction of the exhaust. It's temp to keep the heat/gas away from the intake.
 

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Discussion Starter #28
Another start-up today after adding the IAT sensor (in place of a potentiometer!), exhaust, and gauges. She sounds, and idles
like a champ.

The motor reached operating temps, and no leaks with a pressurized cooling system. Good news there, but the clutch bleeding wasn't as nice.

Here's a scan of the idle (monitoring spark lead). The 0.6 column only
appeared after several minutes of run time. I think the cam is too tame!
Short video to come soon.

 

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Another start-up today. Short video to come soon.
Way to go Tino very nice. But we don't need no short video...........

We Need a Long Video.

Just to up the stakes I'm putting down a "double dog dare" on you to go-kart this thing this week. :devil2:

IF you don't know the rules of a double dog dare, it goes like this

Once you get a double dog dare, you can't not do it :scared:
 

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Discussion Starter #30
You are too kind sir, and I accept your DARE! :devil2:

The clutch is done; the reverse bleed method worked (used a small syringe to
produce the pressure).

Doing the brakes now, and then I should be able to roll-out for a test drive.
You should have a video of that in a couple of days.

We will talk again soon Mr. Body Work. :wave:
 

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Discussion Starter #31
She's done. Brakes, and clutch feeling tight with a little help from my "pressure creator".


Here's a quick video with the new pipes. Don't mind the left exhaust extension, I didn't have it clamped tight enough...or at all!


I'm ready for a road test, but it has been raining for the past two days, and forecasting more tomorrow. Damn those April showers.
 

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Discussion Starter #32
Door hinges arrived today! These things are HEAVY; I'd estimate 25 lbs. per side. Definitely a quality product, but it's gonna weigh me down.

More rain today, and calling for 5-10 cm of SNOW tomorrow! Can I have a test drive soon, Miss Nature?!




 

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Discussion Starter #33
Interesting to note as I've been "studying" my last two log files.

Open tri-y manifold


Tuned 3 inch exhaust via PipeMax


No PCM tuning for either scan. Amazing how a couple feet of pipe can
tame an engine. The software used is called PipeMax. This will all change
once the mufflers, and tips are added. Hopefully there will be enough room
to get a decent harmonic length.

I know my dare is coming due this weekend, but you gotta give me some slack.
Here's the forecast (last few days were rain):
Weather Forecast: Pickering, Ontario - The Weather Network

Maybe Monday to honor the deal?
 

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Discussion Starter #35 (Edited)
Because Mother Nature loves me, even though I'm polluting her environment with open pipes!

Today I was ready for a road test; warm enough, and no rain. My brother-in-law
was here to help out (video, and chase car), but the water temperature started
creeping into the danger zone, so I had to shut it down.

It turns out the valve on the remote thermostat housing is a P.O.S., and the
engine needed about a liter of water to remove the remaining air.

Now that the transaxle is going into reverse (link adjustment), it will be easier
to get out of the garage. The test-run should be a snap for tomorrow, and
I'll be right on schedule for the dare! :001_cool:

Here's another clip of the gear checks, and some rev's
 

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That’s awesome great mile stone!

FYI, i noticed your intake filter it right next to your exhaust. You might was the shorten that pipe a little, I’m sure you’re sucking in some exhaust (i realize it's temporary, just an observation).
 

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Discussion Starter #37
Yes, most of the car is temporary until I can get the road checks complete.

The intake air temp maxed at 5'C (41'F) with an outside ambient temp of 12'C
yesterday.

Normally I have extension pipes on the exhaust aiming upward, and away from
the intake, but you see them on the garage floor in the video. The plan is to
build an airbox once the body gets fitted to grab air from the top of the hatch
where the existing cut-outs are located.

Here's hoping for a better day, and purged cooling system. Maybe I'll get to
ride a little. :checkeredflag:
 

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Discussion Starter #38
Can I Get a Hell Yes?

Finally, with the co-operation of the weather, I was able to get the GTM out for a test drive!

What an awesome feeling to cross this stage of the build. The car behaved
better than expected with fairly decent handling considering the suspension
has not been aligned yet.

The gear linkage needs adjusting as you'll notice that second gear is tough
to engage.

Other than that, just a small fuel leak at the cross-over (passenger side).
It's difficult to see where it's coming from, but it might be the AN fitting
as opposed to the bore in the tank. Either way, it's a 2 minute job to remove
the tank with nothing in the way.


For all the bitching, and complaining I've done, this milestone pretty much erases
all the frustration. If you're going through a tough time with your GTM, push
forward and know that it's all worth the trouble. Having said that, I'm not looking
forward to fitting the glass, doors, power windows, or body work! :glare:

Enjoy the video. Thanks to my wife for video taping, and Rob (the GM neighbour guy) for helping with the second set of eyes. Honorable mention
goes to Erik who we met this evening on his way home. :)

 

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Hell Yes!

Congrats on the milestone! I'm really glad you were able to step up to the double dog dare and take it on .... otherwise I would have had to listen to Presto51 trash talk you all weekend! Seriously, though, well done. Nothing like driving it for the first time to reset the frustration counter and re-energize the build process.

-Michael
 
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