GT-Forty.com

GT-Forty.com http://www.gt-forty.com/GT-Forty/Starter.html This section will cover the fitting of the starter. I wish I could tell you that there is an affordable bolt-in starter but at this time there is not. So I did what any good (Crazy?) car guy would do - I decided to make it work. I’ve taken some cues on this fitting from a friend of mine (Jeff Hamilton) and made some variations on Jeff’s solution to suit my own needs. I decided that I needed to create a device that would not only serve to control the torque of this starter but to capture and clamp it in place as solidly as it would be if it were mounted conventionally. Since I have not yet (noticed I said yet) purchased and mastered a TIG welder where I can weld alloys such as this transmission housing, I need to use my old trusty stand-by STEEL. I’ve not yet finalized the design.. Who knows - I may scrap it and start over. Stock 1989 Starter. With trans in rearward location as originally advised by mfgr - starter solenoid housing hits the RR Lower control arm bolt. When we moved the engine and trans forward 2” it got worse.. http://www.gt-forty.com/GT-Forty/Starter.html#0 c5c370ee-c8e8-4ca0-9361-9a3dd2a8084f http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_0722/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_0722/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-top: 0pt; " class="Caption">Stock 1989 Starter. With trans in rearward location as originally advised by mfgr - starter solenoid housing hits the RR Lower control arm bolt. When we moved the engine and trans forward 2” it got worse..<br/></p></div></div> This is a Gear Reduction Starter bought from an eBay vendor. It’s rated at 2HP and 525 ft lbs torque. It’ll take some work to fit it - check back here later for more pictures and how I make it work.. http://www.gt-forty.com/GT-Forty/Starter.html#1 adb5839e-2b6d-478c-b475-6d771455ae17 http://www.gt-forty.com/GT-Forty/Starter_files/Media/36_1/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/36_1/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_2">This is a Gear Reduction Starter bought from an eBay vendor. It’s rated at 2HP and 525 ft lbs torque. It’ll take some work to fit it - check back here later for more pictures and how I make it work..</p></div></div> This starter came with a Dyno Sheet that showed how it performed during final-test. http://www.gt-forty.com/GT-Forty/Starter.html#2 cd3f03c4-f93e-4d2a-95a3-6121d10c4eb7 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_0982/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_0982/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">This starter came with a Dyno Sheet that showed how it performed during final-test.</p></div></div> Comparison of the new starter to the original Porsche unit. http://www.gt-forty.com/GT-Forty/Starter.html#3 2cac6fdd-ca0a-44ca-8b13-2cd92e782de6 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_0977/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_0977/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_3">Comparison of the new starter to the original Porsche unit.</p></div></div> The new starter doesn’t fit any better than the original Porsche unit but it is smaller and lighter and should be easier to mount in a re-configured location http://www.gt-forty.com/GT-Forty/Starter.html#4 00576828-c677-4300-b2c1-e807f0de4d07 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_0979/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_0979/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_4">The new starter doesn’t fit any better than the original Porsche unit but it is smaller and lighter and should be easier to mount in a re-configured location</p></div></div> The at rest position and throw of the starter drives are very close. The At Rest position is within 1/16” http://www.gt-forty.com/GT-Forty/Starter.html#5 5b7c35c9-0335-4d71-a476-1d0a0314b114 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_0980/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_0980/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_3">The at rest position and throw of the starter drives are very close. The At Rest position is within 1/16”</p></div></div> This is the factory orientation but it won’t clear the chassis http://www.gt-forty.com/GT-Forty/Starter.html#6 c4c98706-aaaf-4d7f-ad11-18a45a1cb2d8 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1454/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1454/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">This is the factory orientation but it won’t clear the chassis</p></div></div> Rotating it counter-clockwise and it clears everything http://www.gt-forty.com/GT-Forty/Starter.html#7 23ccc8a4-8340-4b0e-b6e1-ca6316d35cf0 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1455/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1455/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_3">Rotating it counter-clockwise and it clears everything</p></div></div> BUT There’s no bolts where we need them and this starter cannot be re-clocked to it’s mounts http://www.gt-forty.com/GT-Forty/Starter.html#8 5ceb64a3-329e-49f6-8fbf-e1ffbdeed957 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1456/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1456/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-top: 0pt; " class="Caption">BUT<br/></p><p style="padding-bottom: 0pt; " class="Caption">There’s no bolts where we need them and this starter cannot be re-clocked to it’s mounts</p></div></div> When the eng/trans was still in the chassis, I marked a green line in line with the bolt hole. This shows me where I need to be to clear the chassis http://www.gt-forty.com/GT-Forty/Starter.html#9 c2c0113f-2706-4b72-8e0f-be1d488e6ba5 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1457/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1457/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_3">When the eng/trans was still in the chassis, I marked a green line in line with the bolt hole. This shows me where I need to be to clear the chassis</p></div></div> I rotated the starter all the way counter clockwise so I could use the edge of the mounting relief to catch the starter housing for more support http://www.gt-forty.com/GT-Forty/Starter.html#10 870063de-902e-4edd-a0ad-acbc3d9d8b29 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1458/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1458/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">I rotated the starter all the way counter clockwise so I could use the edge of the mounting relief to catch the starter housing for more support</p></div></div> You can see the housing is very thin here and there won’t be a lot of support for this bolt. I will try to fit a steel nut on the inside to help. http://www.gt-forty.com/GT-Forty/Starter.html#11 9ab1575a-0c25-4f04-ae66-0635adcc2524 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1459/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1459/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_3">You can see the housing is very thin here and there won’t be a lot of support for this bolt. I will try to fit a steel nut on the inside to help.</p></div></div> A Transfer Punch is used to center punch the block-plate http://www.gt-forty.com/GT-Forty/Starter.html#12 ec485907-efe9-48be-88cb-851f0b40afc0 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1463/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1463/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">A Transfer Punch is used to center punch the block-plate</p></div></div> A snug fit in the starter mount helped align the punch http://www.gt-forty.com/GT-Forty/Starter.html#13 eeb30495-9923-4323-8fab-3f18e4dde71a http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1462/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1462/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_3">A snug fit in the starter mount helped align the punch</p></div></div> Marked and ready to drill. This bolt will be a GR8 7/16” http://www.gt-forty.com/GT-Forty/Starter.html#14 c5452868-c9c8-4475-a14f-88e978a18fe1 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1472/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1472/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-top: 0pt; " class="Caption">Marked and ready to drill.<br/></p><p style="padding-bottom: 0pt; " class="Caption">This bolt will be a GR8 7/16”</p></div></div> Transfer punch was too long to fit in the starter on the opposite side so a few minutes with a bolt in the lathe should do the trick http://www.gt-forty.com/GT-Forty/Starter.html#15 bbf5774e-a6ca-4c0a-bff4-6faa8c3fff1a http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1460/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1460/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_3">Transfer punch was too long to fit in the starter on the opposite side so a few minutes with a bolt in the lathe should do the trick</p></div></div> I needed to snug up the fit a little so a couple rounds of masking tape were in order http://www.gt-forty.com/GT-Forty/Starter.html#16 7cdd098e-0285-4edc-9c0b-3c1bf581946b http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1465/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1465/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">I needed to snug up the fit a little so a couple rounds of masking tape were in order</p></div></div> BINGO Notice that the tracing of the hole extends just over the edge of the boss http://www.gt-forty.com/GT-Forty/Starter.html#17 fe547fc3-f0fd-4db6-a52d-4fbd8ed9765d http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1466/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1466/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-top: 0pt; " class="paragraph_style_3">BINGO<br/></p><p style="padding-bottom: 0pt; " class="paragraph_style_3">Notice that the tracing of the hole extends just over the edge of the boss</p></div></div> Close quarters. 90 degree drill was too big so a PIN Vice (finger powered) drill needed to be used to create the pilot hole http://www.gt-forty.com/GT-Forty/Starter.html#18 35d3a6a3-a0d7-4abe-b693-d96b81395604 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1468/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1468/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">Close quarters. 90 degree drill was too big so a PIN Vice (finger powered) drill needed to be used to create the pilot hole</p></div></div> About 20 minutes of finger drilling later - I struck AIR! http://www.gt-forty.com/GT-Forty/Starter.html#19 16035dc4-346f-4c27-bf7c-4428b1c265eb http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1470/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1470/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_3">About 20 minutes of finger drilling later - I struck AIR!</p></div></div> This starter will generate a lot of torque so I set about designing a Torque Strap-Clamp to the 10mm Bellhousing stud http://www.gt-forty.com/GT-Forty/Starter.html#20 5386a699-8f76-482f-be8a-56e9a18daaf0 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1474/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1474/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">This starter will generate a lot of torque so I set about designing a Torque Strap-Clamp to the 10mm Bellhousing stud</p></div></div> 1/8” thick angle iron made the perfect material for the Torque Strap-Clamp. http://www.gt-forty.com/GT-Forty/Starter.html#21 1227b18a-f667-42b4-adc2-0ed69eac6342 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1475/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1475/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_3">1/8” thick angle iron made the perfect material for the Torque Strap-Clamp.</p></div></div> While I will also machine a spacer that is 4.350” to go between the block plate and starter hole, I wanted to extend the torque strap-clamp to the block plate. http://www.gt-forty.com/GT-Forty/Starter.html#22 d57f6993-f1d0-4000-99ed-84464963da93 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1476/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1476/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">While I will also machine a spacer that is 4.350” to go between the block plate and starter hole, I wanted to extend the torque strap-clamp to the block plate.</p></div></div> The starter will want to rotate counter clockwise while cranking but this strap and the starter housing being up against the relief on the other side - I think we’ll be alright. http://www.gt-forty.com/GT-Forty/Starter.html#23 a9e83841-04c5-4f56-8aa4-65d9e83c9959 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1478/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1478/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_3">The starter will want to rotate counter clockwise while cranking but this strap and the starter housing being up against the relief on the other side - I think we’ll be alright.</p></div></div> Welded and cleaned up. I’ll probably powder coat this later. http://www.gt-forty.com/GT-Forty/Starter.html#24 94352d7d-b882-4b65-9a0a-a449edf5885d http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1479/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1479/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-top: 0pt; " class="Caption">Welded and cleaned up.<br/></p><p style="padding-bottom: 0pt; " class="Caption">I’ll probably powder coat this later.</p></div></div> .500” Spacer is .005” shorter than the starter housing next to it. This will allow the Strap-Clamp to tighten down on the housing to clamp it in place without collapsing. http://www.gt-forty.com/GT-Forty/Starter.html#25 c2d21856-4b85-4032-87de-347e3de7c99f http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1485/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1485/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_3">.500” Spacer is .005” shorter than the starter housing next to it. This will allow the Strap-Clamp to tighten down on the housing to clamp it in place without collapsing.</p></div></div> 1.5” diameter Alloy tube cut to 4.350”. http://www.gt-forty.com/GT-Forty/Starter.html#26 56d1bdeb-b127-4047-9a56-e2a0fb0e94c0 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1480/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1480/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="Caption">1.5” diameter Alloy tube cut to 4.350”. </p></div></div> This will support the bottom of the starter housing at the bolt. The bolt is a GR8 7/16” unit. It will be threaded into the block plate and locked in place with a lock nut. http://www.gt-forty.com/GT-Forty/Starter.html#27 470156e8-94d5-4a3e-9b95-98e55b7eb1c0 http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1481/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1481/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_3">This will support the bottom of the starter housing at the bolt.  The bolt is a GR8 7/16” unit. It will be threaded into the block plate and locked in place with a lock nut.</p></div></div> I needed to file a couple of reliefs in the tube to fit up against the bellhousing. No those aren’t cracks in the bellhousing, just casting flaws. http://www.gt-forty.com/GT-Forty/Starter.html#28 12f62680-9164-4baf-b7be-e894a3f6175c http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1484/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1484/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-top: 0pt; " class="Caption">I needed to file a couple of reliefs in the tube to fit up against the bellhousing.<br/></p><p style="padding-bottom: 0pt; " class="Caption">No those aren’t cracks in the bellhousing, just casting flaws.</p></div></div> When it’s all in place, the fit is very tight. http://www.gt-forty.com/GT-Forty/Starter.html#29 7e580916-a17f-4f75-a304-b2c92652a02e http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1483/thumb.jpg http://www.gt-forty.com/GT-Forty/Starter_files/Media/IMG_1483/micro.jpg <div style="padding: 0px; " class="image_cluster_layout_style_default_External_182_135"><div class="image_cluster_layout_style_default"><p style="padding-bottom: 0pt; padding-top: 0pt; " class="paragraph_style_3">When it’s all in place, the fit is very tight.</p></div></div>