3.2 top end rebuild progressing to a 3.4 - basic questions.

[fallingat120mph]

Originally Posted by HaroldMHedge

Erik,



After seeing this photo a while ago, I did some ROW PET digging and found the heat setup appears to be from a Sweden engine. Here's my findings post from 3.2 Twin Plug heater duct clearance

Thank you...just fired up the engine for the first time and hopefully I can piece together the heat from the other thread and what you have supplied.

Of all the things I thought of, rerouting the heat or trying to make it work, this was not at all on my radar.

The new 3.4 runs good on the stand and sounds very very nice


Again, thank you!
Erik

[HaroldMHedge]

Great to hear it's running well and glad to help.

[fallingat120mph]

Originally Posted by HaroldMHedge

Erik,



After seeing this photo a while ago, I did some ROW PET digging and found the heat setup appears to be from a Sweden engine. Here's my findings post from 3.2 Twin Plug heater duct clearance

Originally Posted by HaroldMHedge

Great to hear it's running well and glad to help.

Did you end up doing this modification or just find the necessary parts?

Forgot to ask earlier...


Thanks!
Erik

[HaroldMHedge]

Sorry to say this has been a research project for me since I haven't made my engine into a 3.4. I did think about heating since I had an SC in Malaysia without heat. There I realized that heat is needed for clearing condensation from the windshield during heavy rain.

How I was going to implement this on my 87.

Costly hard to find hot air manifold, 930-211-341-02.


Illustration 108-10
Cut the longer hot-air manifold (930-211-341-03) and adapt it to the hot air manifold (930-211-341-02).

I was going to make the hot air manifold (930-211-341-02) using an SC/930 engine cover air guide 901-106-825-00 (engine tin piece, left) and weld a metal tube to it. And bend it as necessary.

Illustration 202-05
Cut the left side of the Air distributor tube (930-211-335-00) off, rotate the intake 90 degrees (horizontal) then weld it into place.

Use various hoses and hose clamps to connect the pieces.

I hope this helps with your heat.

[fallingat120mph]

Originally Posted by HaroldMHedge

Sorry to say this has been a research project for me since I haven't made my engine into a 3.4. I did think about heating since I had an SC in Malaysia without heat. There I realized that heat is needed for clearing condensation from the windshield during heavy rain.

How I was going to implement this on my 87.

Costly hard to find hot air manifold, 930-211-341-02.


Illustration 108-10
Cut the longer hot-air manifold (930-211-341-03) and adapt it to the hot air manifold (930-211-341-02).

I was going to make the hot air manifold (930-211-341-02) using an SC/930 engine cover air guide 901-106-825-00 (engine tin piece, left) and weld a metal tube to it. And bend it as necessary.

Illustration 202-05
Cut the left side of the Air distributor tube (930-211-335-00) off, rotate the intake 90 degrees (horizontal) then weld it into place.

Use various hoses and hose clamps to connect the pieces.

I hope this helps with your heat.

I almost think the original poster/photo took 930-211-341-03 and cut it making the cut part work to fit "in the corner" and then used a flexible pipe through the engine tin.

I am thinking about cutting a new hole in the tin and doing similar with flexible pipe.

You are right that part 930-211-341-02 is nowhere to be found...per a quick search. Hoping there was a crappy used one out there.

Appreciate the input!

Erik

[fallingat120mph]

Well...first start up achieved:

https://youtube.com/shorts/zxYtIfvcQRc?si=GgXsH7OWoat4Bofa




So, far so good...


Erik

[Cloggie]

Originally Posted by fallingat120mph

Well...first start up achieved:

https://youtube.com/shorts/zxYtIfvcQRc?si=GgXsH7OWoat4Bofa




So, far so good...


Erik

Excellent....mine is a week away. I had no end of issues with the throttle linkage and a few other details.....

D.

[Cloggie]

A solution to the aircleaner issue.....

If you recall, the original Porsche airbox was too tall, so I thought for a while and ended up with 3D printing the bases for each bank, complete with air horns built in.

Plastic is PAHT-CF and is good to 140c and impervious to gas, oil etc. The design work was not too hard as I had the original bases to measure from.

Terribly difficult stuff to print, glad my Bambu could handle it but 10 hour prints per side.

Anyway, some pics. Now I have a place for the oil tank breathing system and fuel vapour recovery system. All good....quite happy.





I made some little ABS snap clips to connect the two. I figure since I oriented the stranding the right way, they ought to be plenty tough.





....and one more....





This material definitely does not print super smooth, but it is sandable and if it works out in action I will probably sand and use some high build primer and SEM Trim Black to make them pretty.

D.

[Glenfield]

Well done. That’s a sensational solution. What year air box are you using?

[fallingat120mph]

Originally Posted by Cloggie

A solution to the aircleaner issue.....

If you recall, the original Porsche airbox was too tall, so I thought for a while and ended up with 3D printing the bases for each bank, complete with air horns built in.

Plastic is PAHT-CF and is good to 140c and impervious to gas, oil etc. The design work was not too hard as I had the original bases to measure from.

Terribly difficult stuff to print, glad my Bambu could handle it but 10 hour prints per side.

Anyway, some pics. Now I have a place for the oil tank breathing system and fuel vapour recovery system. All good....quite happy.





I made some little ABS snap clips to connect the two. I figure since I oriented the stranding the right way, they ought to be plenty tough.





....and one more....





This material definitely does not print super smooth, but it is sandable and if it works out in action I will probably sand and use some high build primer and SEM Trim Black to make them pretty.

D.

Originally Posted by Glenfield

Well done. That’s a sensational solution. What year air box are you using?

You beat me to it! Nicely done.


Erik

[fallingat120mph]

Doing a full suspension rebuild at the moment. Bodywork and paint are done.

Hopefully 3.4 gets installed this week.

Couldn't fit the M&K 2in2out on it with the special 3.2(3.4) Dansk/SSI heat exchangers. Very sad it was a lovely piece. With the heat Y-pipe/crossover pipe there just wasn't enough room. Had a Dansk 2in1out on hand but really wanted a 2 out for the build - ordered a Dansk GT3 style so we shall see...

Found one of the front torsion bars was heavily rusted so for those running originals might want to check. Not sure how it was so rusted. Went with new 19mm up front and 26mm in the back to keep it mostly stock in feel. After a few decades I am happy with the feel of it so for now no major upgrades in that regard.

Had major issues with "new" ignition modules in the beginning. As stated went with Steve Wongs DME update using a single wire to drive a 993 module and my 964 distributor. Found a solid module and the thing runs like a champ - per video I posted earlier.

I may write up something about the process later.


I know this thread has kinda morphed a bit, but I think some of this information can be really useful down the road for others.


I hope to come back here for those seeking out info about 3.4 builds and tell them this was totally worth it. I will say the "while you are in there" has been heavy in this rebuild. You have been warned


Erik

[Cloggie]

Originally Posted by Glenfield

Well done. That’s a sensational solution. What year air box are you using?

Thank you (and others) for the kind words....it certainly turned out better than I had hoped and will share the .stl with anyone who wants it.

I actually do not know the airbox year or anything. I bought it 15 years ago on EvilBay and there is no part number on it.

I also think the existing bases are mismatched as the clips on the mounts do not align with the tabs on the actual air box...the base clips extend far higher than the tabs. I had them clipped to the air box seam before I fabricated this solution.

D.

[fallingat120mph]

Originally Posted by Cloggie

Thank you (and others) for the kind words....it certainly turned out better than I had hoped and will share the .stl with anyone who wants it.

I actually do not know the airbox year or anything. I bought it 15 years ago on EvilBay and there is no part number on it.

I also think the existing bases are mismatched as the clips on the mounts do not align with the tabs on the actual air box...the base clips extend far higher than the tabs. I had them clipped to the air box seam before I fabricated this solution.

D.

Glad to hear it is working out. Hopefully a few of us can chime in after the dust has settled in regards to pros and cons of the way we went with things.

I am having a lot of hiccups, so to speak, the last week of the build, not really engine related but some concerns that might come up down the road.

Mostly bad window seals, suspension updates and old fuel injectors in a basically new engine have been the hold ups....

I'll report back in a few weeks with some thoughts on my 3.4 build, what exactly I improved/replaced/fixed and where I stand on the old 3.2 vs the new 3.4 and whether it was worth it or not.


Erik