Kenik, which rod bearings did you wind up using?

Old stock Glycos. Got reeeeally lucky to find a solitary set.

great work, love the info

Any idea how old they were? I have a set that is a few years old, but who knows when the problems started...

Old. Maybe 10 years old. Maybe more.

Kenik,

Great thread, what an awesome project. I'm going to put you to work sleuthing out paint details on my 77.

Phil

Finally, time for an update!

Things have been plodding along for various reasons - mostly due to me being out of town for work and then vacation. The shop made as much progress as possible on motor assembly in my absence and the long block is finally together:

http://forums.pelicanparts.com/uploa...1417724223.jpg
http://forums.pelicanparts.com/uploa...1417724366.jpg
http://forums.pelicanparts.com/uploa...1417724383.jpg
http://forums.pelicanparts.com/uploa...1417724401.jpg

The ugly red pulley is going out for black anodizing this week.

The heat exchangers, as a reminder, are factory 3.2 Carrera units. This is important because the 3.2 Carrera design was identical to the SC and Euro/late 930 HEs with one important exception: They are 38mm in diameter! They bolt right up to the Euro/late 930 J-Pipe.

At $100 (thanks Pelican!), this turned out to be an affordable, good performing solution that allowed dwindling funds to be invested elsewhere. And yes, they are high heat coated to look puuurty.

With the long block ready, I've been the main blocker on further progress. I decided to save a few bucks by porting the manifold myself (I had a spare '86 manifold...the '79 manifold is going into a box). This led to some delays, given the aforementioned premium on my time.

Doing it myself proved penny-wise, pound-foolish. Ollie's would have done it for $100 extra, on top of the cost of porting my heads. As each hole took 30-45 minutes to port with a Dremel and high speed cutter...never again.

If you're curious how I did it or are a masochist and plan to do this yourself, here are some visuals.

The Fixtures:
http://forums.pelicanparts.com/uploa...1417724670.jpg
http://forums.pelicanparts.com/uploa...1417724815.jpg

The Set Up:
http://forums.pelicanparts.com/uploa...1417724842.jpg
http://forums.pelicanparts.com/uploa...1417724859.jpg

I scribed the cutter lines using a pick I bought from Harbor Freight:
http://forums.pelicanparts.com/uploa...1417724912.jpg

The final product @ 40mm:
http://forums.pelicanparts.com/uploa...1417725002.jpg

Now the final steps of assembly can begin, most importantly by fitting all of the sensors and building a harness for these sensors to interface with the ECU.

My mechanic and I are hopeful that this motor will finally inhale its first angry breaths sometime in January. Stay tuned.

LOVE me the shot of the bare longblock from above w/ the shroud - pure sex IMO

great progress, keep pluggin away...

bored
 

Kenik,
Recently i needed to port out some 911T MFI T'bodies to 38mm to match my 3.0 engine intakes. I ended up buying a BFD..............yes a big f**king drill. It seemed a bit like a klugey way to do it and I thought that I might end up destroying these old MFI bits, but i chocked the drill into my mill and bored those mothers out nicely with low drama and in no time...... a light cleanup afterwards....worked like a champ.

regards,
Al


http://forums.pelicanparts.com/uploa...1417749060.jpg
http://forums.pelicanparts.com/uploa...1417749340.jpg

Al, your method works have been my first choice, but figured chocking up that manifold would have made me crazy without a mill's big table. I'll own a mill one day...

Plodding along over the holidays - not much to report. But I did get ONE OF THESE: :)

http://forums.pelicanparts.com/uploa...1419979108.jpg

Not much is an update, buy if anyone has a cheap BPV to offer up, I'm all ears. Here's mine:

http://forums.pelicanparts.com/uploa...1424334015.jpg

My BPV has the same issue as do most of the used ones I have seen for sale. The threaded section is plug inside the cast material.

Where did you get your owners manual? I ordered one from dealership and they said it would be up to 6 months to reprint. See them on eBay for $600 to $1200.

Got lucky - Ebay, a hundred bucks.

Enjoyed your thread.. great info!! Makes me look forward to taking delivery of my 79 930 turbo next week even more! :D

Great project. FYI I built a very similar motor for one of my 930's and it was really a sweet package. I think you will enjoy it.

If that is Bernie B that is building your motor please tell him Van said hello. He used to work on one of my old 935's when Woody had it . ( I have it back now)

^ Ha, I've sat in that car. I'll say hi tomorrow.

Here is what that 935 looked like when we pulled it out of moth balls and took it to Daytona

http://img.photobucket.com/albums/v6...5/scan0001.jpg

Then we popped fresh bodywork out of our K3 molds and this is how it looked when you sat in it
http://img.photobucket.com/albums/v6...e/DSC00050.jpg

Really a solid great driving 935 but this is the money shot.. unloading at Daytona

http://img.photobucket.com/albums/v6.../intruckwt.jpg

Have fun with your 930 and thanks for saying hello to Bernie for me. He is a heck of a nice guy

The saga has continued in fits and spurts. The motor build has been one that has been full of trials and tribulations, as these things usually go. And as with any non-stock build, has seen its share of unique challenges along the way.

While I may fill gaps in the timeline at a later date, I think it is far more satisfying to share a pic of the assembled motor, in all of its Zork-ey glory. Enjoy.

http://forums.pelicanparts.com/uploa...1428082832.jpg

Nice Kenik....................you're getting me interested in building one of those motors.

regards,
al

Things are really starting to come together. We almost have a runner! Just waiting for a few parts from Clewett and for the stock airbox to come back from the powder painter.

http://forums.pelicanparts.com/uploa...1428434274.jpg
http://forums.pelicanparts.com/uploa...1428434285.jpg
http://forums.pelicanparts.com/uploa...1428434295.jpg
http://forums.pelicanparts.com/uploa...1428434315.jpg

Trans is coming together now, too. New LSD, new 1 and 2 synchros.

http://forums.pelicanparts.com/uploa...1429895202.jpg
http://forums.pelicanparts.com/uploa...1429895223.jpg
http://forums.pelicanparts.com/uploa...1429895242.jpg

I just acquired a hard to find anti-performance part. I am indeed a truly schizophrenic 930 owner. :)

http://forums.pelicanparts.com/uploa...1430090354.jpg

as long as you keep it exactly where it is, that is a perfect paperweight...

It will go nicely with my Thermal Reactor logs...it certainly isn't in my immediate plans to put it on the car.

Time keeps dragging on, and progress is slow and steady, as the pace of work fits the pace of my capacity for cash outflows.

We are almost ready to start talking about firing this bad boy up. The harness from the engine to the ECU and wiring are done, so the motor is ready and we are just waiting for a few items to come back from the platers. Can't wait.

Here are some current photos to whet appetites until then:

http://forums.pelicanparts.com/uploa...1434660674.jpg
http://forums.pelicanparts.com/uploa...1434660686.jpg
http://forums.pelicanparts.com/uploa...1434660694.jpg
http://forums.pelicanparts.com/uploa...1434660713.jpg
http://forums.pelicanparts.com/uploa...1434660724.jpg
http://forums.pelicanparts.com/uploa...1434660733.jpg
http://forums.pelicanparts.com/uploa...1434660743.jpg
http://forums.pelicanparts.com/uploa...1434660752.jpg

That is beautiful- I'm coming to Seattle for a ride-:D
Phil

In September, perhaps? If you fly in, you're welcome to ride shotgun and maybe even take a spin or two.

Looking sweet thar, Kenik (the engine, not you)! :D

Man, too funny about the "anti-performance" York - that truthful comment had me rolling!

Love the 934-like wastegate pipe - I run one like it, buttofcourse.

Looking good Kenik.

regards,
al

Looking good. Where did you end up on CR with those 8.5 JE's?

Is that Rarlyl8's wastegate dump pipe?

CR ended up measuring out at 8.3:1, which is exactly what was expected after the material removed from twin plugging.

Yes, indeed. One thing I immediately noticed after installing it, is that the spacing between my Zork tube, a Fabspeed unit and the dump pipe is pretty wide. Because the Fabspeed is multi-part, it sticks out a bit further.

Yep.. I need to pick one of those up from Brian as well.. love the look!

BTW, Zork and dump tube are both out for ceramic coating to satin black - details, details... :)

Speaking of details, before heading out to the coater, we of course added the O2 sensor bung:
http://forums.pelicanparts.com/uploa...1435255405.jpg

We also trimmed the outlet of the dump tube to match the Zork:
http://forums.pelicanparts.com/uploa...1435255432.jpg
http://forums.pelicanparts.com/uploa...1435255464.jpg

Ahh yes, that does look proper.. and detailed! :)

Here are some shots of the ECU, standalone PLX O2 module and harness getting fitted:
http://forums.pelicanparts.com/uploa...1435255741.jpg
http://forums.pelicanparts.com/uploa...1435255754.jpg
http://forums.pelicanparts.com/uploa...1435255781.jpg
http://forums.pelicanparts.com/uploa...1435255787.jpg
http://forums.pelicanparts.com/uploa...1435255797.jpg

Bye-Bye MSD sticker...
http://forums.pelicanparts.com/uploa...1435255880.jpg

Another detail...the wiring harness will terminate into the engine bay using a few of these nifty Molex automotive quick disconnects:
http://forums.pelicanparts.com/uploa...1435256187.jpg
http://forums.pelicanparts.com/uploa...1435256201.jpg