3.6 964 Project Engine - ideas wanted

[Turbo_pro]

Originally Posted by matty74

Bill do you still have your manifold flanges and injector rails to fit the 964 manifold?

I am in need of a set.

Matt

This might work for you.

PORSCHE 3.6 CARRERA INTAKE FUEL INJECTION 89-91 - eBay (item 250775943316 end time Feb-25-11 14:23:37 PST)

[al lkosmal]

Bill,
I just bought a 3.6 and I'm headed down this path too......update plz...


Regards,

Al

PS: I did Triumph Speed Triple ITBs on a 2.7

[billjam]

Al,
Still plugging away at different parts of the build. I don't get a lot of time, so progress is slow.
Most of my work lately has been on the exhaust system. I built a mock-up using plastic pipe fittings to figure out how I could fit mufflers and heat exchangers and still retain access to COPs and rocker covers. That was a challenge!
I bought mandrel bends, pipe and mufflers and have now finished tack welding it all together. A friend will be over tomorrow with his TIG welder to weld it for me. Once that is done, I will make up heat shields to protect the lower COPs.







I am also working out my MS3 wiring diagram for the 12 Toyota COPs and EFI. There's a fair bit of learning involved here.
One of the problems with the 3.6 conversion that I came across that I hadn't seen covered in any other threads was the placement of the oil temp sender. Because I am using an engine-mounted oil cooler and thermostat, I can't use the standard 3.6 location (where the thermostat is now installed) so I will drill and tap the rear end of the oil gallery and install the sender in the same location as on 3.2s. It's possible to use other sender locations, but I settled for this one as being easiest for me.
I picked up a Clewett cam sensor from another Pelican, so that will go on the LH cam.
I bought a set of pre-3.6 engine tin and I have spent a bit of time panel-beating various parts of it to suit the 3.6 and the rear mount so that I don't have to space the engine mounts lower.

The 911 oil cooler and ducting has been done for a few months. I modified the original 3.6 bottom oil pipe fitting so that I could use a standard oil cooler. You may have seen this in another thread I posted at the time.





That's basically all the progress for now. I've got lots of parts on the shelf so there's never any shortage of areas to work on!

One area where I am still in two minds is the clutch. There are different ways of doing this and I haven't decided which way to go yet. I have a lightweight 964RS flywheel already, but I am having trouble identifying which clutch/pressure plate/release bearing combo will work with the G50 box in my Carrera.
The easy option is to just use a heavy-duty kit to suit the 3.2/G50, but I'd like a lightweight setup and I'm not yet ready to fork out for a Kennedy kit until other cheaper options are discounted.

[0396]

Subscribed…. Keep up the great work!

[DW SD]

any more progress?

[billjam]

Yes.
I have finally started final assembly of the engine.
Over the weekend I fully assembled the heads and refitted all the freshly plated hardware to the crankcase, timing chain covers and cam housings. Fitted new oil gallery plugs everywhere after a thorough clean.
The engine was assembled (without internals) while I finished off the exhaust, sheet metal, fuel and vacuum hoses and wiring harnesses. Man, I can't believe how many hoses and wires I've had to deal with! The hardest thing is to keep it looking tidy and accessible.
It took quite a few hours to figure out the wiring for the ignition, fuel injection and sensors to MS3X. If anyone wants a clear PDF or Visio copy of wiring diagram, email me.



I have had some spare time over the past month, so once I finished making all the external bits and pieces, I disassembled everything and sent out all the parts for powder-coating or replating. Headers are now ceramic coated.
I had the rear end of the oil gallery drilled to take the oil temp sensor and drilled the oil passage between thermostat hole and oil cooler for the engine-mounted cooler.

I can't find latest pics but will add a few when I can ... may be still in camera.
I put these together recently for some other threads ...

[billjam]

Found some more pics.
With coil-on-plug ignition, I don't need distributor any more and I'm too tight to buy Clewett's distributor plug so I made my own. I looked at different ways of fixing it in position and in the end I just made the top end of it a two or three thou interference fit. As back-up for leaks, I also cut a groove for the original O-ring. The M8 tapped hole is for pulling it out if I ever need to.



The oil passages needed to be unplugged and drilled to suit the engine-mounted oil cooler.

Before and after ...




Fitting a thermostat back in the crankcase a'la 911 (in place of the 964 thermostat hole cover plate) necessitated relocation of the oil temp sensor. There are several options, but I chose to mount it in the oil gallery at the rear of the case.

[billjam]

For those looking for cheap way of doing the single belt conversion, here's the dimensions you need to make up a simple bush to do the job.
Keep in mind that the fat end of the bush should be exactly the same size as the original bearing (32OD x 18W x 17ID) and the tapered extension should be same length as the pulley and shims that it replaces.
The bush must be fixed into the original outer pulley hub. If you want to be able to undo the conversion, I suggest a few strategically placed short M6 grub screws screwed radially through both parts. I will not be going back to two belts so I tack welded the two parts together.

[Hebster52]

Any new progress on this?
I'm very interested in your setup! For some reason I almost decided do this to my 2,0 liter flatsix before I found your thread. Still planing on doing it though. Not sure if it will be a bit overkill but who cares...

[billjam]

Thanks for your interest, but no real progress lately except for final clean of parts ready to start assembly over Christmas.

[billjam]

For those of you who have subbed to this thread, I have strung together most details of this build in a new thread now that the engine itself is nearly complete.
I still have to get myself up to speed with setting up and tuning Megasquirt and install the engine in a car - that's my spare time for at least the next six months accounted for!

[0396]

Originally Posted by billjam

For those looking for cheap way of doing the single belt conversion, here's the dimensions you need to make up a simple bush to do the job.
Keep in mind that the fat end of the bush should be exactly the same size as the original bearing (32OD x 18W x 17ID) and the tapered extension should be same length as the pulley and shims that it replaces.
The bush must be fixed into the original outer pulley hub. If you want to be able to undo the conversion, I suggest a few strategically placed short M6 grub screws screwed radially through both parts. I will not be going back to two belts so I tack welded the two parts together.

pm you on these parts

[WERK I]

Originally Posted by billjam

For those looking for cheap way of doing the single belt conversion, here's the dimensions you need to make up a simple bush to do the job.
........................snipped to save space...........................................

Thanks Bill. I've bookmarked so much of your work, seems there's enough to write a book! Great work and detail.
Congrats.

[pat_thonon]

Really impressive. You have a lot of fab. Skills an idea.
I am looking into something similar in the future.

Keep going