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Dsmithmobile
Trainee


Joined: 27 Jan 2016
Posts: 57



PostPosted: Mon Oct 09, 2017 8:41 pm    Post subject: Reply with quote

Think it's a common thing for seized bolts on these,when I fitted my coilovers I ended up grinding off the end off the drop link to get a socket on but was going nowhere so ending up taking the full strut and hub assembly out and put it in a vice and applied heat and got the old lump hammer out and gave it a good beating and eventually came out,good idea copper slipping them up as I did with mine,makes future adjustments or removals easier too Thumb

Look forward to seeing it done Cool
 
  
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markrnorton
Monza


Joined: 29 Jun 2016
Posts: 152
Location: Kent


PostPosted: Wed Oct 11, 2017 12:13 pm    Post subject: Reply with quote

Well, the top mounts finally turned up. A week after when they said they would. Came direct from china so that's why the delay or not.

Bushings aren't quite right so I've ordered an oversize set so I can machine down to fit accordingly.

Also stud pattern for top mount is slightly out, but I knew this would be the case.
will have to fabricate suitable adaptation to car. but will detail on here as I go

be the weekend before anything gets done now.

Also need to clean the TB on the Cayenne, its a bit sticky at low rpm.
It never stops !
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Marky911
Albert Park


Joined: 04 Jun 2009
Posts: 1584



PostPosted: Wed Oct 11, 2017 10:03 pm    Post subject: Reply with quote

You'll get there Mark. Thumb

Can I ask how the shocks are needing so much fettling? Eg different springs etc?

I'm not asking in an arsey internet sort of way Wink , I'm just interested in why the change to the smaller diameter springs, choice of spring caps, etc?

Do they not make a kit specific to our cars then?
 
  
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markrnorton
Monza


Joined: 29 Jun 2016
Posts: 152
Location: Kent


PostPosted: Thu Oct 12, 2017 7:39 am    Post subject: Reply with quote

Marky911
No problem
It appears some kits on the market come with different diameter coil springs
Even though, in my mind, tradition coilovers are 2.25” coils.
This size coil is readily available in different lengths and spring rates

I’ve matched the front spring rate at present that came with this kit, 5k springs or 275lbs in old money. I have have some stiffer springs if required

Also, some of the kits use the existing top mounts, I wanted the sharper feel of the bearing type alloy mount and so having to tweak the tops of the shocks as well

I’ll take some comparison pics later

Hope that helps
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Marky911
Albert Park


Joined: 04 Jun 2009
Posts: 1584



PostPosted: Thu Oct 12, 2017 1:42 pm    Post subject: Reply with quote

Understood. Thumb

Well done on adapting it to suit your exact needs.
 
  
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markrnorton
Monza


Joined: 29 Jun 2016
Posts: 152
Location: Kent


PostPosted: Thu Oct 12, 2017 6:44 pm    Post subject: Reply with quote

So on the left is the spring and old top mount, didn’t want to use this combination

The middle is the ‘exploded’ view of the shock on the right hand side

Spring cap , bush, spigot , top mount, spigot and nut, Plus the damper adjuster

Hopefully this will sit ok
If it’s to high I will have to move to a 6 or 5” spring

Pic won’t load, will sort it later!
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markrnorton
Monza


Joined: 29 Jun 2016
Posts: 152
Location: Kent


PostPosted: Sat Oct 21, 2017 10:03 am    Post subject: Reply with quote

Well the car is fighting me all the way, it’s like it doesn’t want any new parts !
Anyhow only the brake calliper bolts have released so far
Now it’s jus going to have to be cut with grinder or torch, the only nut I do have to release is the drive shaft, I can’t cut or bodge that one off

...prepare the cutters
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markrnorton
Monza


Joined: 29 Jun 2016
Posts: 152
Location: Kent


PostPosted: Tue Jan 09, 2018 5:37 pm    Post subject: Reply with quote

Its been a while since I've had time to work on the car.
Rust and corrosion is the enemy here, seized everywhere.

So I got fed up, and cut everything off !

Mainly with a grinder, but also my plasma cutter as access was poor.
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markrnorton
Monza


Joined: 29 Jun 2016
Posts: 152
Location: Kent


PostPosted: Tue Jan 09, 2018 5:39 pm    Post subject: Reply with quote

So with the hub and driveshaft off, I gave it a good clean up and a bit of paint.
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markrnorton
Monza


Joined: 29 Jun 2016
Posts: 152
Location: Kent


PostPosted: Tue Jan 09, 2018 5:40 pm    Post subject: Reply with quote

New lower arms al la CLR
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markrnorton
Monza


Joined: 29 Jun 2016
Posts: 152
Location: Kent


PostPosted: Tue Jan 09, 2018 5:43 pm    Post subject: Reply with quote

So to the coilovers.
The BC front coilovers use the Porsche upper mount as standard, decided, as per earlier in this thread, not to use them and run with rose jointed top mount. Better location and more reliable. I did have to re-jig the top mount on the wing as the mounts were BMW. so a bit of welding, drilling, and make good painting. All done.
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markrnorton
Monza


Joined: 29 Jun 2016
Posts: 152
Location: Kent


PostPosted: Tue Jan 09, 2018 5:45 pm    Post subject: Reply with quote

Lastly fitted the shock with new springs (2.25") , upper platform and top mount.
rough calculation shows approx. 50mm drop in ride height.
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markrnorton
Monza


Joined: 29 Jun 2016
Posts: 152
Location: Kent


PostPosted: Tue Jan 09, 2018 5:48 pm    Post subject: Reply with quote

Next up is to fit the larger brakes that I picked up off this site from another enthusiast.
Having to get some custom mount brackets machined to fit the callipers to the hubs as originally these were for a C4S/Turbo, so centres and offset is slightly different
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APL911
Spa-Francorchamps


Joined: 15 Aug 2017
Posts: 292



PostPosted: Tue Jan 09, 2018 6:01 pm    Post subject: Reply with quote

Great little project.

Any more pics of the wheels? I was considering these at one point.
 
  
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markrnorton
Monza


Joined: 29 Jun 2016
Posts: 152
Location: Kent


PostPosted: Fri Jan 26, 2018 5:04 pm    Post subject: Reply with quote

Got the brackets back from the machine ship. Nice work of art , cnc'd from the dimensioned drawing I gave them. dummy fitted the bracked (prior to painting)
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markrnorton
Monza


Joined: 29 Jun 2016
Posts: 152
Location: Kent


PostPosted: Fri Jan 26, 2018 5:08 pm    Post subject: Reply with quote

An then the moment of truth, had I got the final dimensions correct for the caliper placement onto the disc. it was tight when I held them up. I calculated approx. 1.5mm either way, so not a great deal of room for error.
I was in luck ! it all fitted up great.
Also, purchased a set of road pads for the calipers (rather than the track pads)

just need to take it apart again now, paint and then refit with some thread lock and copperslip in the right places

I don't think i'll ever need this much power in the brake but they do look good

356mm discs - 8 pot calipers originally for a turbo, but now on a C4
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Harv
Suzuka


Joined: 18 Sep 2014
Posts: 1200



PostPosted: Fri Jan 26, 2018 5:37 pm    Post subject: Reply with quote

Great work and much the same as what I'm doing to fit cayenne turbo Calipers to my C4S.

Would you be able to tell us who machined your brackets and do you know the spec of the ali material used for them?

I'm sure you will be stopping just thinking about it now with 8pots

Thumb
 
  
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markrnorton
Monza


Joined: 29 Jun 2016
Posts: 152
Location: Kent


PostPosted: Sun Jan 28, 2018 12:40 pm    Post subject: Reply with quote

New tech tools in Swanley cnc ‘d the brackets, not sure what steel they used.
Just waiting for a new set of bolts to fit them.

Ordering the brake lines today.

This refresh is starting to add up!
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paul987
Kyalami


Joined: 27 Feb 2015
Posts: 1816
Location: east mids


PostPosted: Sun Jan 28, 2018 9:25 pm    Post subject: Reply with quote

Your doing a fantastic job Thumb

As for the rusty siezed bits I know your pain.. mines been the same lately... as you said it really is like they don't want any new parts sometimes.

Keep up the good work worship
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"Strong minds discuss ideas average minds discuss events, weak minds discuss people. Strong minded people discuss ideas to solve problems." -Socrates

2001 996 C4S - Silver
2006 987 Boxster S 3.2 - Guards red
 
  
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markrnorton
Monza


Joined: 29 Jun 2016
Posts: 152
Location: Kent


PostPosted: Mon Jan 29, 2018 8:51 pm    Post subject: Reply with quote

It’s easy to forget these cars are getting old, 17 for mine.
But the original complexity is still there, unlike old fords!

Onto the last corner soon and then hopefully a shakedown test
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