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Mark's 3.6 Varioram transplant

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Thanks for the offer - where could I source similar for a 964? Is it download or hard copy?

 

I've got one Ben, I'll stick it on my USB next time I see you.

 

Can't see the latest pics but some good work Mark. Why have you decided for the big push now when you've had the VRAM sat around for ages & you're not fitting it for a while?

 

Have decided on a gearbox builder or spec yet? I'm really interested in this part as it's something that is on the radar for me as I'm a bit crunchy like yourself. Also, have you thought about whether you're going to play around with the ratios?

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Why have you decided for the big push now when you've had the VRAM sat around for ages & you're not fitting it for a while?

I had some time available and had no outstanding jobs to do on the car

 

Have decided on a gearbox builder or spec yet? I'm really interested in this part as it's something that is on the radar for me as I'm a bit crunchy like yourself. Also, have you thought about whether you're going to play around with the ratios?

Been talking to MB, next step is to take it to him so he can assess what its like inside and give an idea of costs. No ratio changes planned, all available funds will go on strengthening.

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I had some time available and had no outstanding jobs to do on the car

 

You lucky bugger - Is that really possible?

 

MB's a good choice, I'll be watching that progress with interest. Have you made any calls on strengthening (Wevo?) or goodies whilest it's apart - LSD? I'd imagine you've had a good read of the PH9 rally car thread on here as well then!

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Tiding up the engine loom.


Starting place
vram27_zps728792d4.jpg


A quick snip or two.
vram28_zps7dfcafd8.jpg


All done.
vram29_zps41732a1f.jpg


Some redundant bits - tank vent, fan belt monitoring, heating ballast resistor, heater blower and heating switchover valve.
vram30_zpsbaab468c.jpg

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A bit more.

 

Throttle linkage.


I have never had an issue with the throttle linkage on the 3.2 and so rather than go with the modified 993 cable, or bike cable solution I thought I would knock up something along the lines of what is on the 3.2.
Strangely, the 993 engine not only has the relevant threaded bosses for an earlier throttle crank assembly on the engine case, but it also has three pre cut push-out pieces in the fan shroud, very convenient!

I had an early throttle crank assembly to hand and so tried a test fit.
vram31_zpsbee6bd10.jpg


I dug out some scraps to use.
vram32_zps376fff09.jpg


Made this...
vram33_zps18ca162f.jpg
vram34_zps774f8d75.jpg


...and this.
vram35_zps49d6a962.jpg
And assembled them together
vram36_zps976971ab.jpg


Still needs some finishing, but seems to have the right sort of leverage and operating range.

 

 

 

To be continued...

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Mark, looking very good - i'm hoping this is like time lapse in that you haven't just been doing this the last two days as you've done all of this quicker than I used to wash my 911!

 

To note, what's the flywheel made of? Been a number of issues with lightweight flywheels from certain manufacturers.

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Bracket to support the ends of the oil pipes made and fitted. I used heavy duty alloy with the bends formed hot to avoid weakening it.

vram22_zps006170bb.jpg

 

 

 

 

Good stuff Mark, with the throttle linkage, so long as you have idle and WOT then you've nailed it!

 

I don't know if I would be 100% happy with the P clip holding your oil pipe above as it doesn't really offer that much support. It may be worth looking into something a bit more rigid to prevent stress at the engine end. :twocents:

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To note, what's the flywheel made of? Been a number of issues with lightweight flywheels from certain manufacturers.

Flywheel is steel from Patrick Motor Motorsport in the US.

 

 

I don't know if I would be 100% happy with the P clip holding your oil pipe above as it doesn't really offer that much support. It may be worth looking into something a bit more rigid to prevent stress at the engine end. :twocents:

I know what you mean, but it is what was supplied by Patrick Motor Sport as the best thing to do the job. I will think about an improvement.

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Mark - in the first post, are you saying that JAZ did the cams, rebuild and remap? If so, you will have a good engine. Steve and Dave know these engines pretty well and I know they have done a couple of 3.8RSRs and race motors in addition to the more run of the mill late air cooled stuff.

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are you saying that JAZ did the cams, rebuild and remap?

Yes and the itemised bill from 2004 came to £3,564.38.

 

If so, you will have a good engine.

I hope you are right, it is what I have gambled on.

 

Mark

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Great stuff Mark, very inspiring, wish I had half your engineering skills! Your car will have to be re-christened 'the Silver Bullet' !

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I was thinking about the exhaust yesterday, I have the options of a "self assembly" M&K...
DSCN4528_zpsa93b932f.jpg


...or making something based on a Magnaflow 11386, seen here mocked into place.
DSCN4525_zps8777aba7.jpg
DSCN4531_zpse46e0f4f.jpg


I also have a set of new OE heat-exchanger to catalytic converter adaptors/repair pieces...
DSCN4527_zps643016c0.jpg


..but they will need adapting as they don't line up with where the Magnaflow has to go.
DSCN4532_zpsb75c6ea5.jpg

 


I shall have to have a think about it.

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The magnafow basically just turns into a 'happy crab' if that's the route you take.

 

Tried & tested.

 

Which magnaflow back box is it 14" or 18"?

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Which magnaflow back box is it 14" or 18"?

It is 14", so I a bit concerned about how load it will end up. I am contemplating adding some short round silencers to the outlets (e.g. http://www.ebay.co.uk/itm/Universal-Exhaust-Silencer-4-Dia-54mm-12-WELD-ON-/290581125026?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item43a7fc17a2 )

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Yep, mine is the 14" (11386) and it is fairly loud hence why I made up the baffles/inserts. Perks has the bigger one and reckoned it was too quiet so dunno really. You're welcome to have a listen to mine & see what you think.

 

The magnaflow place also sell some baffles & baffled tips which you may be able to play around with - I have seen this done recently on a 964.

 

http://www.magnaflowstainlesssteelexhausts.com/mufflers/satin-universal-mufflers.html?muffler_position=267

 

Trouble is with the one you've shown is it's a foot long so you may start struggling for space. You could get creative & chop it half though.

Edited by ALEX P

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I have both those setups for my car and the m&k doesnt seem to last very long between repairs for cracks and holes whereas the magnaflow one is just bombproof. Im sure if the m&k was beefed up a bit more it would cope a bit better but i prefer the magnaflow setup so not very motivated to sort it out. Are you planning on using the alloy heat tube along the back of thr engine? Im sure with some angle fettling you can make those parts work, will dig you out some pics when im at my pc later. Ive got onto 105 days with both setups with bungs for the noise test although my m&k is single out.

 

Yr welcome to borrow either/both to copy/try, the m&k will need a small repair before it can be used in anger.

 

Great work on all the other bits, some nice touches :)

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Fitted the intake air temperature sensor into the end of the K&N filter
DSCN4537_zpse816c2fd.jpg

Are you planning on using the alloy heat tube along the back of thr engine?

 

I have got a heat tube, but it is surprisingly heavy at over 3.5kg. I don't have the rubber elbows that connect it to the heat exchangers, they cost over £60 each from Porsche and I guess they would add another 1kg for the pair.


It fits OK with the earlier engine hanger
DSCN4540_zps95fbaa0a.jpg


With the Magnaflow mocked-up
DSCN4544_zps03652dfd.jpg
DSCN4546_zps9b92c19e.jpg


This 75mm flexible alloy ducting may be a better solution. It connects directly to the heat exchangers with a jubilee clip, will fit the necessary routing and is very light. I will just need to make a connector for the pipe from the fan.
DSCN4542_zps848b942f.jpg
DSCN4543_zpsdf3543ec.jpg

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Hi Mark,

inspirational stuff as ever - if you get the chance could you fix the photobucket links please.

would be really helpful to see how you've mocked up the magnaflow

 

thanks

Ben

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could you fix the photobucket links please.

Hi Ben, the links are working OK for me.

 

Is anyone else having an issue with them? If so I will repost them.

 

Mark

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Yes. Issues here.!

OK - here is the whole post again

----------------------------------------------------------------------------------------------------------------------------

 

Fitted the intake air temperature sensor into the end of the K&N filter

DSCN4537_zpse816c2fd.jpg

 

I have got a heat tube, but it is surprisingly heavy at over 3.5kg. I don't have the rubber elbows that connect it to the heat exchangers, they cost over £60 each from Porsche and I guess they would add another 1kg for the pair.

It fits OK with the earlier engine hanger

DSCN4540_zps95fbaa0a.jpg

 

With the Magnaflow mocked-up

DSCN4544_zps03652dfd.jpg

DSCN4546_zps9b92c19e.jpg

 

This 75mm flexible alloy ducting may be a better solution. It connects directly to the heat exchangers with a jubilee clip, will fit the necessary routing and is very light. I will just need to make a connector for the pipe from the fan.

DSCN4542_zps848b942f.jpg

DSCN4543_zpsdf3543ec.jpg

 

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