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Posted

Bloody hell Max, it looks like a brand new engine straight from Weissach :cool:

 

Amazing work, and thank god threads have stopped being about blue chip investments lately and more about cool engineering :)

Posted

Got my cam covers and chain covers back from the paintshop Friday, pleased with how they came out - took a couple of attempts to get a sliver that didn't look too 'bling'... just wanted them to look like clean aluminium:

 

IMG_9201.jpg

 

Forgot to say in last update - I re-used the low-cost rocker shaft seals I came up with last time as they had sealed well to date. For anyone else who want's to try this its just two standard size O-rings, one inside the other:

 

DSC00501.jpg

 

Fits like this:

 

DSC00509.jpg

 

The O-ring sizes I used are as follows

 

Inner: 1.6mm section, 12.1mm ID

Outer: 1.6mm section, 14.1mm ID

 

Total cost for an engine set is less than ten quid.

 

Back to engine assembly... started bolting the newly painted bits on which was satisfying after all the accurate measuring and setting stuff

 

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And chain covers and oil lines on

 

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Next heat exchangers - the wires coiled up are individual cylinder thermocouples.... fitted these a while back when to help diagnose a running problem

 

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Nearly there

 

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And done, more or less:

 

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Waiting for the throttle body to come back from being bored out +3mm - hopefully back by next weekend.

 

Got a few more winter jobs to do before the engine goes back in - one driveshaft needs rebuilding and the fuel tank's coming out for refurb or replacement depending on what I find... neither jobs I'm looking forward to but both need doing before I can start the run-in.

 

Have you ever though about doing this professionally, just awesome attention to detail................

Posted

Bloody hell Max, it looks like a brand new engine straight from Weissach :cool:

 

Amazing work, and thank god threads have stopped being about blue chip investments lately and more about cool engineering :)

 

Cheers Mark - hope you get your engine sorted and back together asap.

 

 

Have you ever though about doing this professionally, just awesome attention to detail................

 

I'd love to but not sure it would cover the mortgage.... maybe as part of an early retirement plan in a few years time though ;)

Posted

Got my re-worked throttle body back today and very pleased with the result.

 

This is the throttle body before machining:

 

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And after:

 

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The throat leading into the main bore has also been re-profiled - now wider with a sharper lip at the top

 

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Main bore is now 66.5mm, up from 63.0mm - so ~11% more flow area

 

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Thanks to Shirish for putting me in touch with the guy who does these - he specialises in BMW big bore throttle bodies but is happy to do Porsche stuff too.

 

On the engine it matches well with the inlet manifold entry:

 

IMG_9237.jpg

 

Seems to blend smoothly with the OE inlet elbow too

 

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Inlet system finished :)

 

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Posted

Hi Matt

 

Very very tasty.

 

With regard to your O-rings, just to be clear, are you saying that you installed two O-rings per groove?

 

Cheers

 

Nathan

 

ps are you still planning on making up anymore AFM's - was it a hot film type (sorry too lazy to do a search)?

Posted

Very Tidy as always Max. Is that a Maf setup? Very Nice.

 

 

Hi Matt

 

Very very tasty.

 

With regard to your O-rings, just to be clear, are you saying that you installed two O-rings per groove?

 

Cheers

 

Nathan

 

ps are you still planning on making up anymore AFM's - was it a hot film type (sorry too lazy to do a search)?

 

Cheers guys.

 

Re the rocker O-rings - yes two per groove with some lube to help them sit right into the groove. The inner O-ring just acts as a spacer/packer for the outer O-ring. I got the O-rings from my local BRT bearing shop.

 

Re MAF: Yes its a hot wire MAF kit using a large bore Bosch HFM5 unit. Not sure if/when I'll get around to making any more kits - the development's done its just finding the time to actually make a batch has proven impossible over the last year or two...

Posted

Love the concept of wider throttle body and MAF. I was very tempted to get a wider throttle body fitted when I had my engine rebuilt and a MAF constantly nags at my conscience.

That looks a great setup Max, very professional looking.

 

The outfit in Norfolk that makes a MAF kit for 944's has also started making them for 964's with good results on the dyno. Hope he starts making them for 3.2's next.

 

...is there a bottom to the slippery slope?....

Posted

Nice job

 

Re the throttle body work:-

 

So he just widens the outer part of the throat - the butterfly itself isn't changed - so doesn't that mean the same amount of air is going in? It's still passing through the narrowest part - the bit with the butterfly in it

 

How much does it cost?

 

Any idea if it would give a worth while improvement without the MAF. I'd be having a remap anyway

 

Just curious about the mod

Posted

Good questions Sladey, I was wondering about it as well.

 

I assumed the butterfly would have a bigger diameter as well.

Posted

Good questions Sladey, I was wondering about it as well.

 

I assumed the butterfly would have a bigger diameter as well.

 

Yes - he the increases the main throttle bore from 63mm to 66.5mm and then makes a new butterfly to match. The throttle entry is also re-shaped to provide a smooth lead into the wider bore. Cost was £120 + return P&P.

 

I doubt there would be much/any benefit in enlarging the throttle if still running the standard VFM as this already has a smaller flow area than the standard throttle:

 

Std flap VFM flow area is 64 x 40mm = 2880 mm²

 

Std inlet throttle area is 63.0mm dia = 3117 mm²

 

Bored inlet throttle area is 66.5mm dia = 3473 mm² (~11% increase in flow area over the standard throttle)

 

MAF kit flow area is 82.0mm dia = 5281 mm² (much bigger :) )

 

Posted

Great job ,looks cool.....

those rocker shafts o ring i use original the cost is $3.00 . I have found out in Europe that a lot of the engines have the shafts on the wrong side(i guess mechanics do not know),so they leak.Or even better it has been sealed with either jb weld or silicone.Very ugly.

I have seen some of the rocker pins get tired and even the o-ring does not help,so it is good to check the status of the shafts.

The curil is super stuff .i use it on transmission rebuilds and the engine just not on the cam o rings( i do not know it is probably ok) i use the orange locktite.

 

Great stuff on the throttle body;-)

 

I hope you post some sounds video of your engine...

 

Ivan

Posted

You really should market some of this kit Max, bet there would be at least 10 guys off here queue up for the MAF kit, including me.

 

Are the stock injectors still man enough to spray enough fuel with the wider throttle body/MAF combo?

Posted

I would say, yes, the injectors are ok. I have the standard ones in mine (replaced at rebuild IIRC) and Wayne didn't mention them as being maxed out at my circa 280+hp. I had 993 injectors on hand if needed, but I am not sure they are any better than 3.2 injectors.

 

If I was doing it again, I would have upgraded the injectors before mapping, but I didn't. Too late now.

Posted

Some more engine progress this weekend:

 

Clutch back on - copper pipe & masking tape clutch alignment tool in action again

 

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All ready to go back in:

 

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And in :D

 

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All ready to go - apart from a fuel tank.... need to finish the refurb on this, so it'll probably be next weekend before I get to fire it up.

 

Posted

It lives :yahoo:

 

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I've rebuilt a few engines but it never gets any less nerve-racking turning the key for the first time!

 

Oil pressure built up fine, took a little while for fuel to come through but still started first go.

 

Think it sounds a little bit deeper and more resonant than before - I guess that might be partly down to the bigger throttle body.

 

Going to hang on till 1st April to tax it so I don't ended up paying a full month and only getting 3days.... roll on Wednesday :steering:

 

Have got a short video clip too but can't figure out how to embed it... what's the trick - I've uploaded it to Photobucket and Youtube ?

Posted

Just copy and paste the link from YouTube? That's what I do anyway.

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