Pelican Parts Forums - Project 930 The Resurrection

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Project 930 The Resurrection

As some of you know my 930 EFI project has been many years and innumerable dollars in the making only to inflict anguish and dissapointment. Many times I thought to just get rid of the car but it seems I can't bring myself to do so. I wanted to share with you the sort of prose that Tom inspired me with to give the car another chance in his brilliantly excuted thread on his EFI odyssey but alas all that is left is a seething anger. I am optimistic that Turbo Kraft will resurrect my 930 from the abyss and once again terrify even the Cerberus with her gnarly growl and terrific performance.

Chris please feel free to document the build here on this thread for all to share and comment on, from the misdeeds to the rebirth. Thanks

Bravo Lincoln, could I bother you to recall some of the history of your car if it is not too painful so we have a sense of where you came from all in one thread so this masterpiece I am sure will come out of this will be that much more magnificent. I look forward to seeing this re-birth as I know you have some high quality parts in this motor already and please do a little pictoral of what the rest of the car is about. Thanks

Outstanding, Lincoln. I'm confident you'll find that Chris and his guys are cut from different cloth. It'll be great fun to watch the progress of your car both here in Phoenix and on Pelican. I'd wish you luck, but with TurboKraft doing your rebuild you won't need it.

I've got to admit, it'll be strange for a while not writing a post every few days. The good news is that you're exactly the right guy to raise the bar a couple more notches. The adventure begins!

Lincoln, good to hear that you're on the way.. I can only imagine how anxious you are to have that car back and producing the kind of reliable power that the sum of your parts should offer.

And of course we're all looking forward to another great build by Chris and his crew!

Paul

Make sure the top end is fresh before installation...replace anything that looks or is suspect, or else the pain of removing an engine...

Schnele, looking forward to follow your build in this thread. Tom's thread was just awesome.

LOOKING FORWARD ALSO!!!!!!! :)

Walt

Plus- I hope TK POSTS- The BEFORE PICS-OF WHAT THE F-WAS GOING ON WITH YOUR MACHINE.

It's not a pain to drop an engine if you know what you are doing! What about an hour and a half max.

I was being facetious, as someone commented privately, "perhaps Tilikum Turbo is a little lost."

I know Lincoln I wasn't referring to you by any means your skills are proven. :D SmileWavy

Quote:

Originally Posted by wjfk32 (Post 5963330)

looking forward also!!!!!!! :)

walt

plus- i hope tk posts- the before pics-of what the f-was going on with your machine.

I know your car has caused you alot of a pain and anxiety bro (understatement)! But glad to hear that will all soon be a distant memory! Subscribing to the awesome build and living vicariously through you.

http://thequickanddirtydirty.com/wp-...0/04/carib.jpg <- on me

That is just what I had in mind Yasin, Lent is almost over and I will no doubt stack a few up.

Just got off the phone with Chris at TurboKraft let's just say it isn't pretty and it is going to be costly I am sure need another set of P&Cs +++ for Chris' benefit here is the purported build components from the last go around with SpeedWerks. Despite my having to go through yet another rebuild I will say Andy McNeil is a stand up guy and I will also state emphatically that David Brown is a lying crook.
Project Type 930/1987 model/ 37343 miles
Engine
3.6 RSA crank and stock oil pump, etc.
Case boat tailed and shuffle pinned
Pauter rods
Mahle 3.4L Cylinders custom JE pistons: 8:1compression
Cylinders and heads ported with custom head work, 964 style head gaskets
930 heads ported with stock valve sizes, but smaller sodium filled 993 valves.
Valves back cut for flow improvements along with some secret headwork
Imagine Auto billet upper and lower valve covers
Twin plug with 12 Bosch FR5DTC Super Plugs
Performance Development valve springs and titanium retainers
GT2 Evo custom grind cams
Carrera 3.2 liter intake manifold Extruded and honed
Wilson 70mm throttle body
Custom billet fuel rails
Edelbrock pressure regulator
Siemens injectors 72lb/hr
Full bay intercooler from Bell intercoolers (Don Enderlein’s design)
B&B Headers (retained)
Fabspeed Dual out exhaust
Limit Engineering Garrett ceramic ball bearing turbo GT37CR
Tial BOV, Wastegate
MoTeC M600 with Data logging
Denso 580 coil near plug coils
Motec switch on the fly boost controller with hidden Valet
Kennedy Engineered Products Pressure Plate/ Porsche Motorsport clutch
Carbon Fiber engine shroud (not that you can see it because of the massive intercooler)
Custom Gauges, tach swings from six o’clock with voltmeter and 220mph speedo
Transmission
Motorsport Synchros and sleeve assembly WEVO G50 shifter.
Suspension
I have upgraded to an RSR coilover setup and Wevo Camber king setup with the strut brace tube.
Braking and Running Gear
The car presently has Big Reds all around and 17” Ruf Speedline classics (8x 10 x17 with Michelin Pilot Sport Cups).
Safety
Full Matter Roll cage and fire suppression is onboard. Bi-xenon H4s, Recaro Sport Toplines in suede and leather, Schroth harnesses full RS interior.
Miscellaneous
I have to have a soundtrack so, McIntosh head unit and amplifier sound system with ADS speakers and JL sub, Griffiths and Performance Aire AC, Custom gauges and an Alcantera Ruf steering wheel, aero mirrors, Ruf pedals and gauges waiting to be installed.

may the force be with you Linc

I see Shadetree edited your last post...some censorship happening?

930 Engine Autopsy

Until Tom's http://forums.pelicanparts.com/911-930-turbo-super-charging-forum/537664-2010-efi-hot-rod-odyssey.html I have tended to not participate in the online forums much. So I was unaware of the heartwrenching saga of the car's past 6 years.

When I first spoke to Lincoln about his 930, I was struck by all the modifications he had done. His build sheet sounded like a recipe with all the right ingredients for a streetable super-930.

Then we got to talking about the power, or lack thereof. It didn't add up.

We agreed to take in the car in the Spring when we were done with Tom's Uber930, to see if we can't figure out what's been going wrong and why the engine just can't hold together.

So without further ado... here we go.

Car arrives, running very rough, dripping, smoking.
Pull the lower spark plugs, and three look wet. Leakdown test results confirm this is effectively a 3-cylinder.
#1 spark plug wire is barely threaded to the plug connector. Same for #6.

A solid 30+ minutes to get the intercooler off. Several different types of fasteners, some obscured; hose clamps, Wiggins clamps, off-angle junctions; lengthy inlet & outlet pipes welded on. Probably an effective unit, but not executed with serviceabilty in mind.
http://forums.pelicanparts.com/uploa...1303370568.jpg

There's metal shavings in the Tial blow off valve. Not a good start.
http://forums.pelicanparts.com/uploa...1303370438.jpg

The first real "WTF???" moment: who molested the Wilson throttle body, and who plumbed it?
http://forums.pelicanparts.com/uploa...1303371117.jpg
- the upper port is boost reference, and is threaded and sealed with pipe dope -- plumbed to the FPR + BOV (bad combination -- the BOV is a vacuum consumer, the FPR is not)
- the lower port is secured with epoxy -- plumbed for the MAP only (good, except the port location makes it very sensitive to airflow over the throttle valve, so it's doubtful it got a good, repeatable MAP signal)
- the side port is pressed in and sealed with clear silicone -- boost source for lower port of Tial wastegate, and a hose going to the cockpit (Motec boost controller wired up by bypassed, old Ruf knob behind seats atop center tunnel access cover)
Plus, the new throttle linkage severely contacts the intake manifold on the 1-3 side. Best case scenario: dangerous. Worst case: lethal.
http://forums.pelicanparts.com/uploa...1303374010.jpg

Raise it up and drain the oil. Crankcase drain plug on the left, oil tank plug on the right.
http://forums.pelicanparts.com/uploa...1303372053.jpg
Those are pieces of piston ring in the crankcase, plus a lot of metal filings. The sludge is mostly assembly lube, but some metal filings.
And the broken Matco 8mm allen socket? Snapped removing the over-torqued axle (CV) bolts.
Just guessing by the amount of torque it took to unbolt the sway bar drop links from the sway bar (I could hang on the wrench), they were probably installed with an impact gun, too.

A closer look beneath the engine and it only gets stranger and uglier.

"Gaskets: if 1 is good, 2 are better"
http://forums.pelicanparts.com/uploa...1303372866.jpg

Why is a 964/993 cylinder head temperature sensor threaded into an adapter threaded into the old air injection port of the cylinder head?
http://forums.pelicanparts.com/uploa...1303373004.jpg

Drop the engine out, and there's the shortened G50/50 from PMS.
http://forums.pelicanparts.com/uploa...1303373618.jpg
Note the modified engine tins over the bell housing, extended on the top surface. That's because the Turbo gearbox is longer than the non-Turbo version, thanks to a larger diameter ring gear. So even though it's shortened, it pushes the whole engine aft by nearly 1 inch if you don't cut & modify the center tunnel. They didn't, and that meant modifying the rear engine mounts of the chassis, latch panel, and engine carrier crossbar.
http://forums.pelicanparts.com/uploa...1303373821.jpg

More 930 Autopsy Photos

http://forums.pelicanparts.com/uploa...1303374740.jpg

http://forums.pelicanparts.com/uploa...1303375005.jpg

Hard to see from this photo, but the transmission bolt was so over-tightened that it has been stretched thin -- deformed -- near the shoulder.

http://forums.pelicanparts.com/uploa...1303374521.jpg

Take it apart in assemblies:

http://forums.pelicanparts.com/uploa...1303374250.jpg

http://forums.pelicanparts.com/uploa...1303374283.jpg

Camshaft (Synch) sensor, re-wired at some point, pretty sloppy.
http://forums.pelicanparts.com/uploa...1303375173.jpg

Oil pressure sensor, leaking adapter for oil pressure switch.
http://forums.pelicanparts.com/uploa...1303374483.jpg

Really weird: loosened this fitting, and it sprayed oil out. For some reason it's holding oil pressure in this circuit...

This is also plumbed for extra engine sensors:
Air Temp -- intercooler inlet
Air Temp -- intercooler outlet
Oil Pressure
Fuel Pressure

Strangely, this car has stock chassis fuel lines -- smaller than -6AN -- but after the fuel filter it jumps all the way up to -10AN in & out of the rails. Then it chokes all the way down to -4AN for the return line out of the FPR. Doesn't make a lot of sense.

http://forums.pelicanparts.com/uploa...1303375518.jpg

The cylinder heads' intake port work actually looks really nice. Except for the speckles of metal stuck to the port wall.
http://forums.pelicanparts.com/uploa...1303375681.jpg

Really nasty oil in the turbocharger scavenge system.
http://forums.pelicanparts.com/uploa...1303375805.jpg

930 Engine Autopsy - Caution: Carnage

Case thermostat bonded in with Loctite 574. Required 2 sizeable prybars to remove!
http://forums.pelicanparts.com/uploa...1303375906.jpg

Metal shrapnel in wastegate lower housing, embedded into valve & seat. Also bonded in exhaust pipe leading to wastegate.
http://forums.pelicanparts.com/uploa...1303376019.jpg

http://forums.pelicanparts.com/uploa...1303376122.jpg

Stacked cylinder base gaskets. This leaked a lot.
http://forums.pelicanparts.com/uploa...1303376445.jpg

Crank angle sensor has made contact with the wheel in the past.
http://forums.pelicanparts.com/uploa...1303376568.jpg

That's a lot of timing marks, machined in and scribed on. Only 3 are needed.http://forums.pelicanparts.com/uploa...1303376654.jpg

Verified camshaft timing during disassembly:
1-3 cam @ 1.99mm / 4-6 cam @ 2.21mm

And the worst of it:
3 - 2 - 1
http://forums.pelicanparts.com/uploa...1303376921.jpg

#3 cylinder
http://forums.pelicanparts.com/uploa...1303377017.jpg

#3 head
http://forums.pelicanparts.com/uploa...1303377098.jpg