I'm currently rebuilding a 944 that I picked up off a friend this summer. It's mostly in pieces now, but this summer I had a blast with it. It's such a great car with classic lines and great performance.

So I'll post up some ideas that I'm working on here to give you an idea about the plan..

Ok, The Protege Project has more than lived up to my hopes. The Car Feels like a street Legal Go-Kart. It looks the way I want and it Just plainly makes me happy to drive. So A New Project is Born.

The Basic Goal is a 300 KM/H Car. It's geared for Top Speed, something I miss in the Protege. The P5 is stellar on the 1/4 or the street, but it's just not fast on the highway. 220 Km/h feels like it's going to Rev to destruction.

E-Bay is the Devil. I have already bought over 20 Things for the car. I will reserve some spots and fire up some sub heading for the diferent projects just like the MP5T Rebuild.

here is a GOAL picture of what I would like the car to end up looking like..



After Cleaning up the 944 it was a great looking car. With over 290,000 Km on the Engine and Tranny. It was time for some TLC.



I removed the entire Fan Blower, A/C. Heater Core. Saved so much weight and the enire dash is empty less the structire.

The day ended with two full size garbage cans full and 10 items being posted on E-Bay.

Ok, Need new fenders for the new 944 Turbo Front that has arrived. The sides are slightly diferent. So I started to pull the shizzy appart. I'm going to get the parts painted seperately off of the car and then assemble them later.

Here is how it looks now. The Car is up and stripped. The Engine is ready to be removed from the car and the tranny is going to be sold for a 1989 944 Turbo Tranny which has much taller gearing.

I'm going to keep the "Widebody" kit but there was some rust it seems behind it. It's ready for a good dose of Sandblast, Prime, Paint, Clear.







The Car is being totally stripped so that only the frame is left. The Front panel, Hood, and Fenders are bring replaced with Fiberglass. The Metal bumper is never going on again. The 87 turbo style front is being swapped on. The metal is being sandblasted and the entire frame is being painted white...

Alright, So here is a bit of a FLAME towards Mazda. I have heard of HORROR STORIES in reference to Auto-X + Oil Starvation = Spun Main and Zoom Zoom Boom...

Did you ever wonder if a Mazda Protégé 5 or MSP could enter the 24h Of Le Mans and survive? The Race is one of the most difficult on mechanical parts ever. A Car can be fast or a car can last, But here... A car must last and go fast. So I do have a point. The Mazda oil pan is Steel and bowl shaped. Almost no heat transfer out and if you are in a hard corner, the oil simply sloshes over to the side and can’t be sucked up by the engine. The 944 has an Aluminum Oil Pan with massive fins (Heat Sink) that would literally suck the heat out of the oil and the oil pan is shaped one inch from the crank and then falls off almost one foot into the sump. It is impossible to starve for oil. By the time the sump is dry, the oil has built up so much that it's litterally falling back into the sump. Perfect. Now the oil pan with Aluminum and heat sink cools the oil.. Why didn't Mazda think of that...Like Hello The 944 that I'm working on is a 1986... they have had almost 20 Years to copy this... Here is the Killer for me, the nail in the coffin as it were. The Oil Pan is mechanically a suitable oil cooler, there is a second Oil cooler, a small "Radiator" style oil cooler, sits in the coolant that is coming from the radiator. No wonder the fucking thing doesn't blow up all over the fucking Track. Mazda... Corner Store, Spun Main, Porsche 944, The "Cheap Porsche" Oil Cooling Overkill. FUCK YES, I'm so impressed I'm beside myself. This is why people spend $50,000 On Sports Cars..

I Turned a Mazda into a Sport Compact. I made many mods to make it able to go fast reliably. Porsche Took a 24H Le Mans race Car and turned it into a street car. Holy Shit, What a Fantastic Idea...

So Here are some Pictures of a totally impressive piece of hardware, It has over 290,000 Km on it and it's hardly showing it, No Scoring on the Cylinders, No Cooked pistons, Hardly any carbon... Brilliant...










I'm Done Ragging on Mazda for tonight..

So Today I put over 5 Hours into the intake Manifold. Some of it is close but I figure that It will get over 20 more Hours to get it to look like chrome.

There are parts in these pictures that have massive scratches from the Rough sandpaper. It's slow going at 320 Grit Wet Sanding and my arms and fingers are simply not able to do any more today...

Bitchn' Manifold Update 15 October 2005






Holy Crap! I think I know why it's called the "CRANK"...

The first person must have seen a Porsche Engine Open and decided to call it the CRANK after becoming Aroused...Randy...





Nov 08/05

Got something a bit special in the mail today.

Normally these stop at 260 Km/h But the 944 Turbo for 1989 had a diferent bag of tricks it seems.. 180 MPH or 300 KM/H

I plan to plant that totally over to the 180 Mark...

Here is some info on the lysholm Supercharger that I bought for the 944. It seems that it will be extremely well suited for high boost applications. Of all the types it seems to be the most capable at adding a massive volume of air but it also seems that it has a negative draw of HP all the time. WHO CARES. The Positives will more than outweigh the negatives according to my Supercharger Counterpart on the Mazda Forums....

The Lysholm supercharger looks similar to a helical Roots blower, but with rotors that are far more twisted, and have a conical taper. The result is that these "screw-type" compressors have an internal compression ratio, making them more efficient in high-boost applications. One disadvantage of this internal compression ratio is higher parasitic losses during off-boost operation. A Roots blower can be bypassed with a simple butterfly valve at part throttle and the only drag will be the mecahnical movement of its gears and lobes (which accounts for only about 0.3 hp according to Eaton). A Lysholm compressor, on the other hand, will continue to compress air as long as it is being turned, even if a bypass valve allows that air to be recirculated. The only way to eliminate a Lysholm compressor's parasitic drag at cruise is to let it stop turning via a clutch. (Ironically, the Eaton Roots blower used by Mercedes-Benz uses a clutch instead of a bypass valve, despite this being the more complicated solution. Mercedes does things its own way.)

There are currently three companies building Lysholm-type compressors, all in Sweden. One is not imported to the U.S., another is sold here as the Whipplecharger, and the third, Autorotor, is integrated for automotive use by several tuners

It's a good thing that my 944 isn't being built for Fuel Economy.


SUPERCHARGER STUFF

I started to work out the location of the supercharger a bit better. As you can see, I have it hooked to the ceiling to support the weight until I get a bracket made. I will attach it to the motor mount and the engine block. The entire assembly will be able to move Front and back for fine adjustment. I need to keep the outlet straight up because of the way the oil is fed and retuned to the Supercharger. Once the supercharger is mounted, I will figure out where the alternator is going to go. One Problem at a time.





I got some time to put the parts more or less where thy belong. I'm not going to get into much detail but you will get the basic point.

I'm totally impressed worth the Parts from GT-Racing, They are expensive, but the fit is great, they are strong and most important. They weigh close to nothing. The Nose panel is a bit stronger than the fenders, but I understand that it is the leading edge of the car and I'm happy that it is stronger at to cost of a bit of weight.

The Headlight conversion is just placed there. There is clear plastic the covers the bucket. I'm simply waiting on the 951 bumper shocks and then I'll fire it on the actual car for a better test. I do not think I'll be disappointed.







Tested out the basic look of the car. I'm like a kid with a new toy.

Got bored and ripped more of the Porsche interior, seats and carpet, in Prep for Bodywork.

The more I get done now, the less time it will need to be prepared at the shop. Time is Money...

I also got the 25L fuel cell today!

The entire front of the car has converted parts for the 951 style fiberglass from GT-Racing, Literally are 6 Lbs
Steel Bumper gone for the 951 Aluminum.
The Headlight Motor and Linkage are gone (Fixed Headlight Conversion)
The Hood is being swapped out for fiberglass
The rear seat and the interior dampening under the carpet have been removed including The deadliner Hard Rubber cover that lines the interior of the car.
The Heater and A/C complete are out of the car leaving a hollow dash.
The fuel cell has been removed/replaced by a 5 Gal, as well as all the lines and pump/filter.
Rear Carpet with Stupidly Heavy Rubber Liner Gone.
Fuel level sending unit gone.
Power steering Pump and lines gone.
Battery is being replaced with a 5 Lb battery.
Stereo is removed,
Passenger seat is out but can be replaced.
The stock 16" rims are back on.
Wiper Delete,
Steel Exhaust is being replaced by a short.
Under the fenders Porsche lined the car with a thick rubber coating. Removed Auto Central Lock,
Power Windows being swapped for crank.
Trunk Popper removed and replaced by a Cable.
Cruise Removed.
Misc Brackets...

Now Things like the Carpets and Seat are Removable and Replaceable so it will still be very drivable as a summer car and will retain the Oh So Sexy look of a Porsche.

The plan is to use Black Speaker Box Carpet and Contact Cement it directly to the metal all over the rear of the car where the back seat was all the way to the trunk. If done properly, it will look Ok but weigh nothing..

Here is the basic idea for the 944 Fuel Delivery. The car is capable of unreal cornering that will only be better when it's 2100 Lbs. I have designed a system where the fuel will not slosh to one side during hard cornering. The 5 Gal will feed a 1 Gal with Double outlets. This will serve as a "fuel buffer".
During cornering even if the fuel in the 5 Gal is on the side of the tank, the 1 Gal will still be full. When the car goes level again, it will top up the 1 Gal.

The second Fuel tank is on the way with the Stainless Braided Fuel lines.



Ok, SO Here I finally have both together. I still can't believe the difference Bore Over Stroke makes in an Engine.
Mazda Piston -
4 Banger Small 2.0L Long Stroke

Porsche Piston -
4 Banger Large 2.5L Short Stroke

I believe that the Porsche piston is just unreal. I know that there is nothing Magic about the Word Porsche. The engine is still able to break, you can still kill it with PSI and Bad fuel management. I just think it's very cool how well it is designed to last and be driven hard.







Got tired of the lighting in the Speedo.

Replaced them with 9 Blue LED..

The picture catches harshness that is not apparent.

Looks great and I have more to iluminate the Autometer.





It's about time for an UPDATE I think...

Lots of little things have happened since my last post.

I have found out that I am moving to Ottawa this spring... 1200 Km to Ottawa.

The 944 has to be able to Run by July 06 so I have to put the Paint on hold.

The original idea was to have the engine compartment the same color as the car and that was going to be done the same time the car was painted. Now I am in a rush a bit and I have found a solution that works for me as well.

I bought 100 Sq, Feet of B-Quiet Aluminum coated engine bay noise killer. It's Sticky on one side and aluminum on the other. When heated it is easily applied to the firewall with a roller and looks stellar.

So the entire engine bay will get lined with this material. That gives me the freedom to paint the car without having to take out the motor again once we arrive in Ottawa.

Here are some pictures of the Deadliner.





I got the badly abused center panel of the stock Recaro seats recovered. The center panel used to be Super 1980 cool ORANGE, but I think that the Black Looks super.



So You all remember the headlight conversion...



I installed two Hyper White LED bulbs in each as my DRL..







This is also finished..

The Driving Light Holes were removed, backed by fiberglass and filled level with bondo..


BEFORE



AFTER


March 07 2006

This might make the entire Engine Bay Idea a bit clearer. It's far from finished, I am getting the first layer on and then I have a second roll to make it stronger in places and cover up some stuff to make it look nicer.





March 09 2006

Started major work on the interior. The Headliner is being replaced and starting from the front to the rear it got half done but then it started to be too cold to continue. Tomorow is supposed to suck so later for pictures..

Today I bid on an won a 944 S2 clutch as the original one that came off my 944 was down to the rivets. Out on a limb a bit, the S2 clutch is diferent looking but I think that it will be compatible with the stock Flywheel and pressure plate that I have. The deal was too good to pass up..



E-Bay Link

I think for $60.00 it's worth it..

March 10 2006

Here is a shot of the work.
You can get a feel for just how low and long this car really is.

The frame is sitting about 3" Higher than normal because the motor etc... is not installed.
SEX ON WHEELS

Can't wait till it's done. It's a bit cold today so not much going on in 944 Land.



March 12 2006

What great weather to work outside!

Today I finished the headliner. The old one simply sucked and was ripped to shit. I used the same material that was used to recover the seats. I think it looks great, All the edges are covered and the material is thight and not coming down any time soon.

Here are some Shots..





I got the last of the heavy cracked and useless "Factory Noise Killer" off the inside of the car and replaced it with the same light weight aluminium that I have been doing the engine bay with. The Old stuff was 20 Years old and had split all over so it was useless and heavy. Not a good combination.

I'll post up some pictures of the finished product as I get them..

Here is the bare metal.



06 April 2006

Update.

Motor going in this weekend...

Interior Rebuilt....

Both doors open and the trunk works now.. :)












April 11 06

Updated picture of the Weekends work.

There are some Misc bolts holding stuff together that are the wrong length on the Fuelrail etc, and most of the sensors have to be hooked in but the hard part is done.



May 07 06

The Back End Is together..


The Fuel Cell is going to fuck alot of people up. It's totally visible.. :)



14 May 06

Fiberglass Fender Fitment and Installation ALL DAY..

They are solid and are about 6 Lb rather than 60... Wicked!

May 20 2006

Today got the bulk of the rear the way I wanted it.

I installed a manual release handle behind the passenger seat. When pulled, it opens the rear glass hatch...

Basically...
1. Less Wiring
2. Less Weight
3. Less "Something To Go Wrong"

Works like a charm.

The thick black carpet has been replaced with the same stuff I used throughout the engine bay...

It is going to cut down on the "Green House" problem of the 944 design.

I only did the left side today but you get the point..

__________________

UPDATED CARDOMAIN FOR THE MP5T

56K hates you.

Nice car though!

nice car im definitely liking how it is looking

Makes me want one more

It's 20 years old and still looks like sex on wheels.. :)

Fell in love with it when I was a Boy, Never thought I would ever own one..

__________________

UPDATED CARDOMAIN FOR THE MP5T

doing a great job....can't wait to see some video of it running :P

that car is some hot shit, well worth the weight on my 56K right now, speaking of which i sware my modem just sighed after all that

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1989 Toyota Celica ST165 GT4 3SGTE 2.0L TURBO (Under Construction, Engine Rebuild, Bigger Turbo, big FMIC) :rockwoot:
1994 Jeep Wrangler 4.6L Stroker (The Desert Rat)
1997 Fiat Brava 1.6L (The Euro Beater)

^^ Thanks. I can't wait to paint it..

__________________

UPDATED CARDOMAIN FOR THE MP5T

May 29 2006

Fuel System is finally coming together. The 5 Gallon has two AN8 Steel Braided lines that hook to the 1 Gallon tank. Each of those is hooked to a Tee fitting. One goes to the engine and one returns. Basically, even if there was only a gallon of fuel in the car, it would be almost impossible for it to starve for fuel around a corner. This was done solely to save on weight. The beauty is that there are no different settings or configurations for holding more fuel. Simply fill up the 5 gallon and your set.

The fuel lines are AN-8 (One Inch Steel Braid) through the fuel filter until they reach the MSD EFI Fuel Pump. Then the lines are stepped down to 3/8" steel braid, they travel the fuel rail and run 3/8" until the collector where the lines get stepped back to AN-8 and connected to the in port of the 1 Gallon Tank..

__________________

UPDATED CARDOMAIN FOR THE MP5T

Im gonna drive up there and finish this car for you!!

Fuck im impatient!



looking good!

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:bd: -Randy

Political/news Forums clicky here!!

I never liked thew 944, but you are doing a great job with this one.

__________________

Thanks..

You quickly start to see just how cool it really is when you take one appart and see how much they actually thought about when it was designed..

__________________

UPDATED CARDOMAIN FOR THE MP5T

too many pictures :blowup:

Un-Subscribe :bash:

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UPDATED CARDOMAIN FOR THE MP5T

May 31 2006

Fuel System:

The Double Feed is hooked up. The two feed into Tees that go to the front of the car, One is Supply and one is Return.

The vent line at the top is to make sure that the 1 Gallon is full all the time and the one way check in the system makes sure that noting will spill out. Next up is the Filter, Pump and Fuel Rail.

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UPDATED CARDOMAIN FOR THE MP5T

I havent been on MSprotege.com in a while...

any different pics over there?

__________________
:bd: -Randy

Political/news Forums clicky here!!

purty (i spelled it that way on purpose)