Snap...crackle...pop...ROAR!!
 

OK, so today I turned the key! And turned it, and turned it, and turned it. After investigating, I discovered that my injectors had pressure and my ignition was sparking correctly, but due to a lack of extra "oomph" from the cold start mechanism (isn't running, don't know why yet), the engine couldn't start. I shot gasoline straight into the intakes with a spray bottle while cranking, and the car fired right up. I discontinued use of the spray bottle, and the engine continued running strong on its own, firing on all six. The sport exhaust is insane. This engine really has an amazing sound - it snarls, growls, and roars. No tinny or raspy sounds at all; its all throat.

So far the only oil leak appears to be from a valve cover. Score!

Needless to say, I'm bouncing off the walls with happiness today. I haven't had a 'running' Porsche 911 since... Jan 2000??? Wow, 4 years. So a shoutout to:

-Pelican forums and the ever-positive Pelicaners
-Dempsey for his engine book
-Tyson Schmidt and John Luetjen for helping to 'design' this engine
-My long-suffering wife
-Tim (aka wrench monkey)


Here's a pic:
http://forums.pelicanparts.com/uploa...1070067600.jpg

Nice eh??

Here's also a photo of the first oil change. Any thoughts, comments, etc? It shimmered with metallic flakes.


http://forums.pelicanparts.com/uploa...1070067674.jpg

Congrats Dave! There's truly no better sense of accomplishment,no matter how long it takes! I bet it sounded great:)

cam lube maybe?

Great news there, Dave! Hope those flakes are not of any consequence.

The sound of that engine is great. I got a phone call yesterday afternoon with an unmistakable purr mixed with a loud smoothness that only a sport muffler can sing.

Congrats on getting that beast to roar! I guess Its about time to do the same.

Jamie

Good job on the rebuild. I bet the roar is satisfying, I thought adjusting my valves was pretty cool!!

My oil looked the same for the first two times (2nd, not as bad as the first). I also think it was all the assembly lube coming off. After 4 oil changes, it now looks completely normal.

That oil looks so bad, you'll need to start over on the rebuild... just kidding. I'll bet it smells funny too. That's normal. It's a great feeling, isn't it... That exhaust looks great, I'm sure it sound great too.

Alway's great to see a MFI roar back to life. I like the comments and look of the sport exhaust. I am considering modifying the two in one out presently residing in my laundry closet, you may have just convinced me!

Excellent Dave! Let us know when you are on the road with it and we'll celebrate by having another Carolina Fun Run. :D

Hi Dave

What are your driving impressions of the sport muffler and MFI engine combo? Any flat spots?

I've heard good and bad for using these mufflers with MFI - especially that they do not have enought back pressure.

Dave's on his was to allentown today, but I can answer for him after having driven it for more than a few miles. The sport muffler was designed to work well with the MFI. If there is a flat spot at 3K I didn't notice it. He and I LOVE the sound of the sport muffler. It's really pretty tame at idle and without much throttle, but when you get into it it roars to life and has a really mean sound to it.

more later

My oil looked like that when I changed it the first time, after running it for 15-20 minutes.

Its all the assembly lube.

And yes, it does smell funny.

Here's a link to a sportmuffler sound file I've got (not this car's though)
www.uncg.edu/~tpwalsh/graywolf001.wav

thanks guys

does anyone know if baffling in the danske 2 in 2 out (centre pipes) is any different than the 'home made' ones people make up from old standard mufflers? (ie. seal the side outlet, add the two centre pipes and cut some extra internal holes)

i ask because old standard mufflers (and welders) are much easier to find in Australia than danske products

Ryan,
As mentioned above, I LOVE the sport muffler. You'll find me around town in mostly 2nd and 3rd gear, just so I can listen to that wonderful engine. I've got an almost-unnoticeable flat spot when transitioning from part throttle on overrun to WOT. It is very difficult to reproduce as the conditions usually aren't right. I don't know if this attributable to the sport muffler, inherent limitations in WWII injection technology, 30 year-old pump needs rebuilding, or 'T' space cam mated to my Crane tuner cams.

NO idea about the Dansk guts. The best thing about building your own sport exhaust from an old muffler, is that the existing baffles are already nice and rusty. They flow better :D

Incidentally Ryan, and those interested, here's a link to 3 recordings of my freshly-built engine with sport muffler. 1st two are in-car, 3rd is a drive-by outside of the car. Great Doppler effect on the last one.

Dave

many thanks - i'm trialling a mate's spare stock muffler on the weekend. if that improves things then i think a dual centre out sport muffler is on the cards. of course - all results will be reported here.

it worked!!

http://forums.pelicanparts.com/porsche-911-technical-forum/182146-mfi-flat-spot-fixed-freakin-sport-muffler.html

Great! Are you going to try converting the OEM Bischoff to a twin-pipe sport muffler now?

Dave

I think i'll keep this one and the car and find another to experiment with.

I've also got a design for a 2 in 2 out setup using a pair of hot dog style mufflers i'd like to try.

Congrats Dave, 4 years is a long time to wait. I just put bolted the rods on and am right in the throws of a rebuild 2.4 MFI from my 72 car. Nice to hear the success stories.

The motor will be re-debuting in a few months with a fairly thorough detailing to go with the freshly painted tub. I hope to debut pics soon...

As an update or epilogue on this motor:
This motor has run great, but has been rather leaky. Tracked one leak down to a pinched thermostat o-ring which was making the the flywheel seal look guilty. That helped a lot. Still some oil dripping on the heat exchanger from somewhere though, which wasn't cool. Then, misc. wetness on valve covers.

The motor has been yanked from the car for the repaint and continued restoration after logging a couple thousand miles. Upon inspection, the MFI cam seal is dry, the flywheel seal is dry, and nose seal is dry. All good news!! Yet to be inspected are: oil cooler, oil return tubes, rocker shafts, and various case joints & misc. One definite leak is at the right bank cam tower adapter - the sealing ring is crushed. Too much torque - I will be torquing these 'by feel' from now on and tightening a bit if they leak.

Anyway Cassidy good luck on the rebuild - definitely check out my site for some good newbie rebuild advice.

Very cool - congrats!

-Wayne

Dave;
You know, I missed this thread originally. I'm happy the motor turned out well. I loved the sound files. Congratulations! You're inspiring me to get moving on my project. But first I have to get some more parts out of my garage!

- John

John-
Just make sure none of those parts end up in my garage and we'll all get along fine! It's just starting to get back to the point where I don't get all nervous and twitchy when I turn on the light out there. If my garage were Walmart, it'd have been sued many times from people getting bonked on the head from top-shelf fallout.

Propane torches are heavy and blunt when bouncing off your head from the top shelf.

Moving along quite nicely today on stripping the last bits of paint off the car and finishing up metalwork. Dropped six hundred bones this morning on paint and supplies, and that didn't even include the base and clearcoat. Ouch.