Jacob's rebuild thread

[jwasbury]

Hopefully I get to drive my car again before its all over

Got the stinkin' intercooler fitted:


To address fitment isses, I made up some brackets of flat steel stock a la home depot:


Its quite a big lump with the IC installed:


Fan and alternator installed...now its ready for transport:


Loaded up in the Uhaul:


Engine and chassis see each other for the first time in 6 months:


Next up...reinstallation. Hey Vinny! What'r you up to next weekend?


Parting shot...Installed the momentary switch and LED for the datalogger in my aux gauge panel.

[WERK I]

Tip - If you find that when you close the engine bonnet, the rear of the IC is very near to the grill opening sheet metal, you can grind the mounting bracket holes that mount to the cooling fan housing. Just elongate the holes an additional 1/4"-1/2" and that will give you the clearance you need.

[pkracer21j]

I'm loving the olive drab fan housing! I never would've thought of that! keep the pics coming Jacob. can't wait to see your review of her back on the road.

[Mark Morrissey]

Jacob, it was great to meet you at McSorley's with the rest of those nut cases Tuesday night. Thanks for the invite to check out your car; I'll have to take a rain check as I have to work Saturday and then will be heading out to visit family Sunday. I absolutely want to see that beast close up in the near future.

And, wow, what a great thread. Unbelievable, fantastic, inspiring job. You have my utmost respect. We'll be in touch.
Regards, Mark

[jwasbury]

Saturday was the big day...

Had a little trouble with the ignition system as documented here:

Electromotive XDI2 - help please

Got it fired up and heard an ugly, ugly sound. It seemed to be the top-end. I opened the upper valve covers and all was fine...but I was done for the day. I spent Monday at work obsessing about all the thousands of ways I could have screwed up.

Took the day off today to investigate the noise and went straight to the lower valve cover. Found that the locknut on the #3 adjuster had backed off and allowed for a huge clearance. Locknut was sitting at the bottom of the cam housing, waiting for me. I sang praises to the Porsche gods, reset the clearance on #3 (took the opportunity to check 1 & 2 while I was in there). Fired her up and all is right with the world. Did the cam break in, put in fresh oil and went for a ride...got about 14 miles on the rebuild now.

A big thanks to my friends who helped out along the way. Here is a boring video of it running:

[9dreizig]

SWEET!!! Good job Jacob,,
Now back to work on that hole in the water you pour whatever money you have left into!!(nice boat btw,, we should have a NYC turbopalooza on it!!)

[billjam]

Originally Posted by 9dreizig

SWEET!!! Good job Jacob,,
Now back to work on that hole in the water you pour whatever money you have left into!!(nice boat btw,, we should have a NYC turbopalooza on it!!)

We are! (although I haven't let Jacob know yet! )
Too bad you're too far away to join us.

[Ed_]

Wow, SMOOTH! She sure sounds a lot better now than she did on Saturday with that wacked-out tappet.

She's so shiny... Did you get any pictures of her with Vin's flame job?

[smurfbus]

Woohoo, great news about the noice. So scary to do the first startup and then hear something ugly.

How do you figure the nut had loosen?

Is 11AF the norm when after startup?

[MikeD930]

Congrats Jacob! I was wondering what's up with the ugly noise you mentioned earlier. I was hoping for the best. Good to hear it's no problem.

[jwasbury]

Todd...the boat is CHEAP compared to the car. I could have a small fleet of them for what I have into der Turbo.

Smurf...the AFR is normally pretty rich at start up, but leans out as the bimetallic strip in the WUR does its thing. I have done 0 tuning at this point so its not set up yet. Stay tuned, plan to get to a dyno very soon. As to pinpointing the source of the noise...it seemed to be coming from the top-end, but man was it LOUD. I had all sorts of scary thoughts like valve-piston contact, wristpin circlip dislodged, etc. Vinny, a fellow pelican who helped with the engine suggested it was probably a loose adjuster.

Funny story: My state inspection expired while the car was off the road for this rebuild. Yesterday as I was getting back from my first short drive, I passed a Jersey City cop (motorcycle patrolman). He made a U turn and pulled me over literally just as I was stopping in front of my home. He asked for my license, registration and insurance, and then asked "what's up with your inspection." I explained that this was the first time the car had been on the road in about 7 months. I was in my grease stained carhart work pants, the passenger seat was out of the car (for access to the new electronics mounted underneath), so the officer believed my story immediately. He was obviously interested in the car, so we ended up chatting about it for 10 minutes or so. When he was ready to leave he recommended I get it inspected immediately, and he also said "you didn't hear this from me, but I suggest you take this thing out and show up the guys in their Hondas and Toyotas"

[krasuskyp]

Jacob! Congrats! That is soooo hugely cool. Wow, that muuuuust feel gooooooood!!! I'm srsly impressed, no way Jose (nor hose B) could I endeavor the same. Very well done.

and

ROFLMAO getting pulled over immediately. And afront of home. And @ the convo. Priceless!

Looking fwd to hearing your tune results. Good luck, enjoy!

[juicersr]

Attttaaaboy Jakester!!!!!!!!!!!! Huge congrats buddy!

There is NOTHING like the feeling of sitting in a car listening to the sound of an engine you put together purr along, except maybe after the first time you got laid.

Priceless story of the Jersey cop.

What is going to be your break-in regimen? The consensus for my N/A motor seemed to be to drive her pretty hard, with lots of right foot followed by lots of hills and down shifting to seat the rings well.

[A930Rocket]

That's great news Jacob. It's always good to find out it was something simple after doing some major surgery...

[Ed_]

Wow, sounds like a greuling routine, Justin. Are you supposed to have more fun breaking her in than during normal driving?

Jacob, you don't have the decel valve in yet, right? That is probably better for break-in then, eh?

Originally Posted by juicersr

Attttaaaboy Jakester!!!!!!!!!!!! Huge congrats buddy!
What is going to be your break-in regimen? The consensus for my N/A motor seemed to be to drive her pretty hard, with lots of right foot followed by lots of hills and down shifting to seat the rings well.

[onboost]

Jacob..

Good work and congrats man!! Get the break-in miles on it so you can spool-it-up properly!

Paul

[9dreizig]

Jacob,
Sorry I didn't go through the whole thread,, how much did they soak you for the K intercooler ?

[jwasbury]

Break-in regimen will be to not pussy-foot it.

And I've already hit a little boost Paul...a sec or two and not full. My first drive was on surface streets and I pretty much had it in 1st the whole time. Rev'd it up and then engine braked back down.

I'll get it out on the highway this weekend and the plan is to vary the revs as much as possible. I'm trying to schedule dyno time next week, so it will really get broken in then

Todd, the intercooler was around 2k all said and done. Although I did have it shipped by air from Cali so it could be installed in time for a certain gathering of turbo fools in North Carolina last summer Of course it didn't get installed and my shipping $ was a waste, but that's another story.

[RarlyL8]

[Vin-barrett]

Oh thats what it's supposed to sound like....
Great job Jacob, maybe i'll catch up with you this weekend