Porsche 924s Water-pump, Rack, Front Wheel Bearings, Engine Mounts

After I lost the Waterpump earlier this year, I took the opportunity to work on some other pending issues with "Big Red", my 1987 924S.

Water Pump purchased through Amazon - Uro model. Many bolts sheared. Used Helicoil inserts and one bolt had to be re tapped at M8 -- a massive size for such an application. Other 10 bolts remain M6, and I removed all studs.

Rack requested through South Carolina-based Rack Dr.
Testing the rack now. (Not the easiest outfit to work with) System is still moaning/groaning, but there is no fluid loss that I can identify. (reservoir remains full)

Update 10/2019: Rack appears to be functioning correctly, although the alignment of the splined turn gear seems to be off in a way that prevents the original bolt (M8) from fitting. I substituted a M6 to get clearance to install and have kept my original rack (not the moaning culprit as it turns out) if I need to in the future.

Alignment performed after installing the rack

Engine mounts from Uro installed (Amazon or Pelican)

Control arm ball joints replaced. (Pelican)

Tie rod ends replaced. (Pelican)

Fuel Jumper line replaced (Pelican) - alleviated fuel smell for now

New Sway Bar Bushings (Pelican)

At this time, the Power steering pump is being suspected as the moaning/groaning source as I've replaced every other component in the system including new lines (with exception of the fluid cooler) and a rebuilt rack. Additionally, following my alignment, I need to tighten the tie rod end nuts as those were reported loose. (now done, but still hearing a popping sound when turning under load)

Information Sources Used:

(1) Clark's Garage (Great man with a huge contribution to 944 owners everywhere. Rest in Peace Clark)

(2) Front Wheel Bearings (Floating Frame Calipers)
https://www.youtube.com/watch?v=apBUNIl4HNw&t=425s

Update: Clunking Noise when steering

10/4/19 Update: I've noticed a clunking sound after installing the new front suspension. The root cause appears to be the suspension ball bearing which I regreased and light sanded some galling on the inner race which abuts the strut shoulder. Seems to have fixed the issue in my trials. Pelican/Porsche wants $107 per side new for these rubber with bearing assemblies -- better to make the old ones last.

Getting alignment done was a $200 exercise because they figured out that it was a Porsche -- I don't think that they even touched the camber for that price.

Update: Clunking Solved by grease-packing front strut bearing.

10/12/19 Update: The clunking was fixed by removing the left strut and repacking it's bearing with grease.

1st Oshkosh

One of the many fly-overs

Icon Aircraft is based in Vacaville CA, and assembles there. Many Components built in Tijuana, Mexico

Attention to detail

Long-Easy resting nose down to avoid tipping backwards due to wind

F35 aside a B-17

A plane if designed by Salvador Dali

1/4" Dyneema Amsteel 12 Strand Eye Splice for Standing Rigging (Hobie 20)

[See Article on this Blog Titled" "Amsteel Dyneema Stretch"]

12 Strand Amsteel/Dyneema Eye Splice
https://www.youtube.com/watch?v=EjR4E_91txk

Brummel Splice
http://atlanticbraids.com/dyneema-brummel-eye-splice-1-end/
https://www.youtube.com/watch?v=d0B6tYTVHVM

2nd End
https://www.youtube.com/watch?v=fIR5JdQ7TEo
https://www.youtube.com/watch?v=IxSi8igfChk
https://www.youtube.com/watch?v=4WW7Qvg3VjI

Hobie Side Shroud Length: 23' 5 & 1/4" [7.14375m]
Additional Length Required for Splice: 1.5ft
Total Length required for 2 Eye Splices: 26.5 ft approximately.

Shrouds / Stay Length
https://static.hobiecat.com/2010_archive/support/pdfs/WireGuide.pdf
My measurements in meters / mm:
Side: 7.135m (7135mm) -> Shorter better to allow stretch and adjustment -- 6.8m
Fore: 6.335m (6335mm) -> Now measuring about 6m to have adequate tension

https://smallboatsmonthly.com/article/synthetic-fiber-rigging/
https://www.apsltd.com/aps-advisor/types-of-eye-splices-for-braided-line/


https://www.youtube.com/watch?v=_r-6pjTE3Qc

7/29/19 Update:

I've installed the stays and they were not exactly the same length, but close enough (a few inches) so that they could be adjusted by the side-hole adjuster. Next, I'm going to work on the forestay replacement as dyneema is much easier to work with.

9/16/19 Update:
 Amsteel stretches 1 to 1.5 feet per 22 feet of 1/4" line.This must be taken into account when determining line lengths, and lashing adjustability shoudl be built-into the design for tensionning. I lash with 7/64 amsteel, use 1/4" Stainless thimbles (316) and take 4 lashes around for an expected strength of 4* 1600 lbs = 6400 lbs (2909 kgf).

10/4/19 Update:
See this article about how the rigging looks: http://porsche924s1987.blogspot.com/2019/09/dyneema-rigging-pictures.html

Checkride Preparation

DPE Selection
https://www.aopa.org/news-and-media/all-news/2017/may/flight-training-magazine/checkride-selecting-examiner

Prepare to:

Know your airplane and all of its systems, including Autopilot if equipped.

Know your airspace rules and procedures (Charlie / Bravo radio acknowledgement, Bravo must be cleared into Bravo etc)

Know your night and day flying limitations. 90 day rule with landings for night flying etc.

Practice maneuvers such as steep turns, slow flight, stalls, approach descent and landing items.

Aviation Parks and Land with Runways

America is unique in that flying from place to place is actually possible on your own. With roads filling with cars and congestion, the dream of taking to the air has never been so appealing than in 2019.

Links to Aviation Property:

California
http://www.aviationacres.com/californiaairports.asp

North And South Carolina
http://www.carolinaairparks.com/w_airstrips.htm

Oklahoma
http://airportproperty.net/airok.htm

Stage 7 Check C172SP

--> Clearing Turns [Always do them]
--> Set Flight Following before Taxi.
--> Use Taxi Diagram
--> Briefing

Engine Failure in Flight
Vg 68. Best GlideSpeed
Fuel Shutoff - In
Fuel Selector - Both
Restart (if time/altitude permits)
--> Aux Fuel Pump - On, Mixture - Enrich, Ignition Switch Both
--> Start (if Prop stopped)
--> Aux Fuel Pump - Off (if restarts)
Check Fuel Flow, if Zero Aux Fuel Pump back on

-> Airspace Categories. C and D require 2-way radio contact to enter. C requires also Mode-C Transponder.
-> Pilot and Equipment Requirements
-> Bravo (B) Airspace requires explicit "Clear into Bravo"

Special Use Airspace.
-> MTR - Military Training Routes
-> WARM-PC. Warning, Alert, Restricted, MOA, Prohibited, Controlled-Firing Area.
Restricted: Unusual often invisible hazards such as aerial gunnery or guided missiles.

Flight Systems:
-> KLN94 GPS
-> Autopilot Usage

 Cessna 172SP Airspeeds:
Vspeeds
40-Stall speed full flaps
48-Stall speed no flaps. "Clean Configuration"
55-Rotation Speed no flaps. "Normal Takeoff"
62-Vx Best Angle of Climb for obstacle clearance
68- Vg Best Glide Speed
74-Vy Best Rate of Climb
105- Va. Maneuvering Speed at Max Gross Weight.
110- Vfe. Flaps 10 Max Speed to deploy Flap 10 Deg.
129- Vno. Max Structural Cruising Speed. Beginning of Yellow Arc.
163- Vne. Never Exceed. Red Line on Airspeed Indicator.

Airspeed Indicator
 40-85   White Arc: Full Flap Operating Range
48-129 Green Arc: Normal Operating Range

Source: https://forums.x-plane.org/index.php?/forums/topic/153898-cessna-172-airspeed-indicator-grey-arc-at-bottom/

Weather
https://www.cfinotebook.net/notebook/weather-and-atmosphere/weather-fronts

Ice Pellets on surface indicate: Temperature inversion with rain falling through colder air which then freezes during its descent as ice pellets.

Thunderstorms can form on warm & humid days.
Top reaches 40,000 feet or more. --> Cannot climb over.
Supercell - Tornadoes can result.
Multicell - also called Squall Line. Multiple Thunderstorms

https://www.faa.gov/documentlibrary/media/advisory_circular/ac%2000-24c.pdf
Mature Phase- both up-drafts and down-drafts. Microbursts are down-drafts.

Source: https://www.weather.gov/iln/skywarn_guide

Anvil Cloud of Thunderstorm
https://www.weather.gov/iln/skywarn_guide

Lenticular Clouds
https://en.wikipedia.org/wiki/Lenticular_cloud

Altimeter Setting
-> If not available, adjust to departure airport.

Approach
-> Pilots of inbound aircraft should monitor and communicate 10 miles out

Airspace
https://www.faasafety.gov/files/gslac/courses/content/25/185/vfr%20weather%20minimums.pdf

VOT
http://www.askacfi.com/3681/vot-vor-test-facility.htm

Preventive Maintenance:
https://www.cfinotebook.net/notebook/rules-and-regulations/preventative-maintenance

Questions
FAA advisory circulars containing subject matter specifically related to Airmen.
60

924S Waterpump Bolts Sheared. Resources

8 Waterpump Bolts and 4 studs, length 45mm.
http://www.mcmaster.com/#93275a014/=2qgbbj
50 mm M6 Studs for waterpump

Extractor also necessary if you can't back the sheared studs or bolts out.
These I purchased from Harbor Freight.

Left Hand Twist Drills can also work with drills that can run in reverse to remove bolts.

If your radiator is in place, you will need to use a short drill or angle drill. I found one at Harbor Freight for $30 which was excellent. Link to Drill.

In one case, my extractor itself broke. This required a carbide "burr" (search on Amazon) to be used with the drill to remove the hardened steel insert. The process was time consuming and led to the problem of "enlarged bolt hole"

For bolt holes which are too enlarged, I use Stanley Helicoil, a tap kit to allow stainless inserts to thread into oversized holes. My Helicoil (only 1 needed) was for M8!
Clean and re-clean the gasket surface, and use a new gasket with your new waterpump. My replacement came from URO on Amazon.