Project 930 The Resurrection

[TurboKraft]

Originally Posted by drmatera

Chris, you don't leave a stone unturned... that's a rare quality

Thanks.
Kinda how it has to be, though, right? We don't want this to go "bang" on our watch, so we're double-checking anything and everything. Lincoln (and this car) have been through enough, and I know I speak for Lincoln, too, when I say I want this to the the last time this is apart for a long time.

[drmatera]

yes, judging from his prior experience there was a quarry of stones unturned.. And we saw how that turned out.

As always we anticipate your next post (with pics?? )

[SCHNELE]

At least at the quarry there would be some stones turned over so I believe you are doing a disservice to the quarry. Chris is absolutely correct I cannot undertake another such ordeal with this car.

[TurboKraft]

For most of our builds, we do not use the stock factory compression rings. How many times do we see these 930 engines having to come apart because of broken rings? As jwasbury aptly put it, “the 48 piece piston ring.” They break so easily they might as well be made of glass. The rings we use are much harder and flex instead of breaking. They require file fitting to get appropriate end gaps.



Mike uses an electric ring grinder to make the process a lot faster. Use at your own peril -- these remove material very quickly.



A common mistake we see is the cylinders’ bores not getting cleaned properly before assembly. One spray of carb or brake cleaner doesn’t do it. The nikasil and cross-hatching holds a lot of oil and compound left over from the honing process. Don’t clean this out thoroughly, and you’ll destroy the rings and pistons in no time. (Charles at LNE has some scary and sad photos of engines killed in a matter of hours.) Even the last set of Mahle Motorsport pistons & cylinders we got needed extensive cleaning. We have found diluted dish soap works best to start, and then 3-4 more cleanings with solvent and a microfiber cloth.

Weigh all rods, pistons, and pins on a gram scale, then start matching to get everything as close to the same as possible (that’s all the writing on the top of the tool cart). The factory tolerance is up to 9 grams difference on rods – which is a lot when the engine is spinning at 6,000+rpm. Once the melted aluminum piston was removed from the Pauter rods, they were within 1.4g, the pistons within 0.5g, and pins within 0.3g. After matching, each rod+piston+pin assembly is within 0.6g.



Decided to add to the solid dry film performance coatings to the pistons:
* low friction coating to the skirts
* oil shedding coating on the bottom of the piston to help carry away hot oil
* low friction hard coating to the piston ring lands
Make them as durable as possible.





Clean the case one final time, check all dowel pins are in place, install bearings and apply assembly lube, install the oil pump and seals, intermediate shaft and new Motorsport timing chains, apply the Loctite 574.

[vas930]

Sweet!
Thanks for the detail, Chris.

[billjam]

Really interesting. Thanks for sharing Chris.
Good info regarding cleaning of bores. Those compression rings you use sound like good value too.
Keep it coming.

[TurboKraft]

Shiny ARP goodness.
And a plug for Pelican. :-)



Case webbing radius machined (prior build), cylinder surfaces machined, new piston oil squirters installed, Pauter rods (prior build).



Case fittings reinstalled with Loctite threadlocker, new pressure relief valve pistons & springs.



This pulley has way too many marks scratched onto it, and the outer A/C groove was machined but not re-anodized. We’ll verify the alignment of both grooves with the fan pulley and compressor pulley, make sure they are correct.



The back of the pulley also interfered with the #8 nose bearing, so we machined it for clearance.



Custom pistons & LNE “Nickie” cylinders installed.




(Fun job in the background, a turbocharged Boxster S getting a lot bigger engine.)

Bagged when not worked on.

[TurboKraft]

More photos to come, but the heads are on, too. Niresist rings (aka flame rings, LeMans rings) installed. Time to test cylinder leakdown before continuing assembly…

[WinRice]

Very Nice!

And I thought only old american V8 builders hand fit ring gaps.

I didn't see any bosses on the cylinders for cylinder bridges, is this build getting knock sensors?

[TurboKraft]

Charles of LNE is working on incorporating knock bosses onto the Nickie cylinders, which would make them just that much more awesome.
But in the meantime we're machining the heads to utilize twin OEM knock sensor assemblies (1/ea left and right bank). We did this for Tom's UBER930, Fred's 3.4L EFI, and a dozen other 911/930 engines. Seems to work well.

[jonesb930]

Originally Posted by TurboKraft

Charles of LNE is working on incorporating knock bosses onto the Nickie cylinders, which would make them just that much more awesome.
But in the meantime we're machining the heads to utilize twin OEM knock sensor assemblies (1/ea left and right bank). We did this for Tom's UBER930, Fred's 3.4L EFI, and a dozen other 911/930 engines. Seems to work well.

Chris,

What is the cost and turn around for this machine work if I send you my heads?

[TurboKraft]

Originally Posted by jonesb930

Chris,
What is the cost and turn around for this machine work if I send you my heads?

$140/set, most of that being set up time on the mill.
If there's anything else you need done on that face of the head, like surfacing or niresist rings, that's the time -- each head will already be set up square for machining.

[onboost]

Originally Posted by jonesb930

Chris,

What is the cost and turn around for this machine work if I send you my heads?

Originally Posted by TurboKraft

$140/set, most of that being set up time on the mill.
If there's anything else you need done on that face of the head, like surfacing or niresist rings, that's the time -- each head will already be set up square for machining.

Thx for asking and answering that question... I'll have some heads out to you Chris sometime in the future!

[MikeD930]

Everything's looking good! I've hand fit rings before by using a nail filer on my other car. Talk about nerve wracking and time consuming experience!

Chris, what brand are the piston rings? JE's?

As for adding grooves for flame rings don't both the heads and cylinder need to be modified together? Oh wait...I reread what you wrote...only the heads needs to be modded if you get LNE cylinders with grooves already in them. What would the charge be to machine a set of stock cylinders (or any other cylinders without grooves) for flame rings in addition to the heads?

[tom84930]

Lots of terrific stuff as usual, Chris. You and Mike make it look easy, but the truth is that there must be a thousand different ways to screw up these builds. Just consider the disasters Lincoln experienced in the past. Damn, what a pleasure it is to see something done with such uncompromising excellence.

[TurboKraft]

Thanks, Tom!

Originally Posted by MikeD94

Chris, what brand are the piston rings? JE's?

As for adding grooves for flame rings don't both the heads and cylinder need to be modified together? Oh wait...I reread what you wrote...only the heads needs to be modded if you get LNE cylinders with grooves already in them. What would the charge be to machine a set of stock cylinders (or any other cylinders without grooves) for flame rings in addition to the heads?

Yes, file fitting rings is very time consuming. And these are crazy hard, like trying to file stainless steel.
Nope, different ring supplier.

Flame rings: LNE supplies the cylinders un-cut, no grooves. If he's offering to machine grooves in the cylinders, we didn't know -- and it's likely it wouldn't be a match to our specs.
We have been making our own rings for some time mow, and milling the heads & cylinders to suit. Rings available for 95-97-98mm cylinders, and 100-101-102mm cylinders. Typically $600 to do heads + cylinders + rings.

[SCHNELE]

I am getting good vibes about these steps that you are taking Chris and hopefully I will get her back before the white stuff flies.

[slow&rusty]

Originally Posted by SCHNELE

before the white stuff flies.

That's next week in Michigan..ain't it?

[SCHNELE]

Not quite but before too long it will be here.

[cole930]

Jesus Chris, that thing is so pretty, if it weren't for the thought of that first ride I'd put it under glass an sit it on my coffee table.

Absolutely perfect !!!!!

Cole