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Join Date: Jul 2016
Location: Ayrshire, Scotland
Posts: 46
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Spenny, I've just read your thread from start to where it is now, I've never come across such a comprehensive engine rebuild and major engine modification thread, I can't help but thinking that you've just had some major bad luck recently, and now you've just had to strip your engine again and have gone about it as though all you've had to do is pull some spark plugs.
Major respect mate, I hope you get to the route of your problems and .... Wishful thinking that it won't cost an arm or a leg, I'm sure you'll get it fixed and I look forward to reading about it when you do. |
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02-08-2017, 01:37 PM
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Kartoffelkopf
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02-14-2017, 01:01 PM
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Also for me at the moment, but she will be magnificent! What is even more crazy it is that I have already in mind the future evolutions, the passage of which in EFI with "among others" the kit proposes Chris ...  In brief, we do not finish it! I wonder if it is not sick ..., we live only once. Courage Spencer. Patrice |
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02-18-2017, 02:21 AM
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Fantastic Build, Your work is amazing, any updates ?
I'm putting back my 965 for road use, I don't remember how the right side heater blower motor is installed, Would you be kind enough to take some pic's of your right rear heater blower motor mounting for me. many thanks. Good luck with your build
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1986 944 turbo -first car 1997 993 Cab 6 speed-sold 1992 964 C2 turbo SOLD, 911GT ,CIS, 428 fwhp 450 trq, Carrillo rods, 964 cams, TT retainers,7.5 comp 1.1 bar boost 320 ml black fuel head 009 injectors, 044 pumps, 60-1 T4/T3 dual scroll turbo |
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05-05-2017, 06:12 AM
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Kartoffelkopf
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Yes, there's some stuff happening in the background in terms of re-working the cylinders and getting new pistons ordered, as well as some loom re-working. Chris is looking after the metal bits; the cylinders and old pistons were sent over to AZ for assessment, then over to LN Engineering for them to get the cylinders round again, and re-plated. I've been deliberately holding-off on hitting the "Go" button to order the pistons until we knew that the cylinders were fixable (they were, of course) and frankly, until funds allowed. Some unexpected other expenses in the meantime, which will become clear in time; a little bit Brexit related, where it made sense to commit before the exchange rate worked against me. Quote:
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Last edited by Spenny_b; 07-10-2017 at 12:04 PM.. |
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05-05-2017, 06:39 AM
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Kartoffelkopf
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Evening folks, project revival time....although in reality it's been constantly alive in the background to me....but nothing that makes particularly interesting reading whilst things are happening.
So..."what has been happening?" I hear you ask... A week or so ago, I received a nice big couple of boxes from good old Chris and the gang at TK! 1) A set of reworked cylinders 2) Beautifully coated CP Carillo pistons 3) Some new Ni-resist flame rings 4) A set of TurboKraft rocker shaft locks 5) A pair of Z blocks; I now have 2x Mitutoyo digital DTI's, so why not be able to mount both simultaneously onto the engine? 6) A set of Stromski cam chain tensioners (I really didn't like using some G-clamps to try and do this the last time I built the engine...a bit too unrepeatable for me) 7) A Wrightwood top-end gasket set 8) 4 sets of cylinder base gaskets, various thicknesses, in order to dial-in the compression ratios.  Speaking to Chris over the last year or so, it very much made sense to ask the guys to look after the whole-shebbang, seeing as they're looking after getting the cylinders reworked, and spec'ing the pistons. So, Mike (TK) has looked after the ring-gap setting, thoroughly cleaning the cylinders (i.e., mega-cleaning them to ensure no honing residue is in the grain of the cylinder walls), and then assembling the pistons into the cylinders. Piston assembly is something I have done dozens and dozens of times before, on many engines, and a few times on this engine whilst building it the first time.....but...such is my paranoia with making abso-bloody-lutely sure this second rebuild goes perfectly, that asking TK to ship them over to me pre-assembled means that it's another thing off the list of things that can go wrong. Also worth noting that the rings on these new pistons are now 1mm rather than the previous 1.5mm. The crown and underside is also significantly different from my old Omegas, they look mega, really pleased with them. |
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08-06-2017, 03:13 PM
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Kartoffelkopf
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So this weekend was my first opportunity to actually get started with the rebuild. First job was to think about how to accommodate the pair of knock sensor bridges I bought many moons ago.
Mulling over several options, and after saying to Chris that I was determined to keep the 3x heads & cam housing all built (to save time with the rebuild)....it turns out I couldn't keep it all in-tact. Firstly, mounting the whole thing upside down to them machine the 3x mounting holes was very tricky. Not having a proper mill with a bed that's big enough to mount it, is the limiting factor; my pillar drill is uber-heavy and more than ample to do light milling duties, but my X-Y table just isn't big enough to mount it. So....time to break it all down, remove the cams, rockers, shafts and then separate the heads from the carrier. This needed the use of my floor-standing hydraulic press....  A nut onto each of the head studs (to save damaging the studs), and then a 13mm socket with an additional nut inside it, and a 3/8" extension bar, and it was all freed up very easily. A lot more elegant and less risky than smacking it with a hammer. The cam housing will be fully cleaned up in due course, but onto machining the underside of the heads. Unfortunately I don't have a 16mm spot-facing tool, so I used my 8mm end-mill to machine a square landing area for the bridge to mount onto. Heads clamped down nice and tight, and the job's a good'un....   Refit the heads to the cam housing to mark the hole centres...  Once marked-up....  ...time to then re-mount each head for drilling and tapping...  Lovely job. I'll clean the cam housing before re-fitting the heads and checking the bridge mounting. This was for just the 1-2-3 bank; tomorrow night it's time to do 4-5-6. Should be quicker, as I now have the procedure sorted, blocks of wood at hand, machine clamps set up, etc, etc. |
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08-06-2017, 03:37 PM
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Very satisfied to reread you Spencer, I wondered what you become!
 Pat |
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08-07-2017, 12:23 AM
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Kartoffelkopf
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08-07-2017, 01:18 AM
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Welcome back. Always love to hear your updates.
Sent from my Nexus 6 using Tapatalk |
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08-09-2017, 11:41 AM
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Kartoffelkopf
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08-09-2017, 01:39 PM
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Kartoffelkopf
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Oh bollocks....
....just when things finally get underway again, and decent progress is being made (and frankly, my enthusiasm has returned)....
 Running into the house to answer the phone after a nice BBQ outside on Monday evening, enjoying the summer evening whilst watching the Athletics, smashed my toe on the sliding door frame, then completely lost my footing on a wooden floor. Didn't even manage to get a foot down to break my fall, before going down like a sack o'(you know what) onto my left arm. Hurt like hell, and an x-ray yesterday confirmed that I've broken the top of my radius ("radial pivot"?) in my elbow, as well as my toe. I thought I'd also fractured my wrist, but think its perhaps just a sprain. Thankfully it hasn't displaced, so I didn't need it pinning, but...This. Is. A. Complete. Pain. In. The. Arse. Not only can I not do any engine work, but I'm not allowed to drive (legally in the UK...insurance is void), meaning I've had to cancel the summer holiday in the Vendee in western France. I think my daughters being more circumspect about the loss of holiday than me, she's been great with helping out (as has all of my family)....but I can't tell you how fed up I am. 6-8 weeks of inactivity. Last edited by Spenny_b; 08-09-2017 at 03:01 PM.. |
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08-09-2017, 02:01 PM
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Forced Induction Junkie
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Sorry to hear of your mishap. Hoping for a speedy recovery. In the meantime, we'll have to figure out a way to turn that frown upside down.
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Dave '85 930 Factory Special Wishes Flachbau Werk I Zuffenhausen 3.3l/330BHP Engine with Sonderwunsch Cams, FabSpeed Headers, Kokeln IC, Twin Plugged Electromotive Crankfire, Tial Wastegate(0.8 Bar), K27 Hybrid Turbo, Ruf Twin-tip Muffler, Fikse FM-5's 8&10x17, 8:41 R&P |
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08-09-2017, 02:52 PM
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Ugh. Get well soon.
Sent from my Nexus 6 using Tapatalk |
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08-09-2017, 03:26 PM
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Really no chance, courage Spencer and good recovery! ;-)
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08-10-2017, 01:48 PM
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Moderator
Join Date: Dec 2001
Posts: 9,569
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Hmm. . . breaking your Radius. . . is not Humerus. (Anatomical pun!)
Sorry mate but breaking your arm is no excuse. . . 6-7 weeks of inactivity is 6-7 weeks more rebuild research! I'll say it again Spencer. . . the entire global community of Porsche enthusiasts is WITH YOU in this moment. . . we've been following your progress for YEARS and we are not about to quit now. This too shall pass. . . broken bones will heal and the fire of frustration will die down. Maybe it will take a long time. . . but I know you, and I know you will Never Ever Give Up (to quote a famous Bulldog). Hang in there. . . post Xray of shattered bone with West German stainless pins installed. . . Take Courage and remember that WE are with you.
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'66 911 #304065 Irischgruen ‘96 993 Carrera 2 Polarsilber '81 R65 Ex-'71 911 PCA C-Stock Club Racer #806 (Sold 5/15/13) Ex-'88 Carrera (Sold 3/29/02) Ex-'91 Carrera 2 Cabriolet (Sold 8/20/04) Ex-'89 944 Turbo S (Sold 8/21/20) |
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08-22-2017, 01:01 PM
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Kartoffelkopf
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Alas, no x-ray pictures, nor any need to pin it (like Lucys arm, if you remember?). That's what I was dreading. No plaster either, as it needs to remain mobile or else be locked in position. It's getting so much better each day, I'm really pleased. Not quite able to extend arm outstretched fully, nor can I fully bend it. When walking without the sling, I do resemble an AWOL Thunderbird who's puppet strings have been cut, lol. For the first time this evening I can now use both a knife and a fork simultaneously!! (just). Wrist rotation is getting a little easier, and lifting light items is do-able. Laptop bags into London on the Underground, however, is still too heavy. First fracture clinic appointment this Friday, so we'll see what the prognosis is. We have a public holiday on Monday, so a long weekend coming...I'll certainly be having a go at resuming works. In regards to following the project for years, yes you sure have, and I'm very grateful for everyone hanging-in-there with me! I've started posting "digest" updates on Instagram recently (of course, limited at the moment)....look me up if you want as "spenny_porsche" and with the tag of #spennybengineproject The next job will be to look into a replacement service for Photobucket, as I read the other night that they're now starting to charge outrageous amounts per year for an account that allows image hosting onto forums!! |
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08-22-2017, 01:29 PM
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Kartoffelkopf
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Okay, time for a petit-updatette....
Last weekend, after spending a very nice chilled out few hours in my back garden, enjoying the sun, watching various sports on the iPad...I got a little fidgety and could resist no longer the temptation to do some engine work. First job, finish off the drilling and tapping of the holes on the underside of 4-5-6 cylinder heads. A gentle test of arm strength, and all was good, working very slowly in a considered manner. [Sidenote] My arm had been healing really well for the last 3wks, and a consultation with the fracture doctor the day before had been very positive, even going so far as to say that I could try driving (in a safe empty car park), and if in full control, then I could drive on the roads again. His parting words were that unless I fell on it again, I won't displace the fracture at this point in the mending process.....(you know what's coming next, eh?) [/sidenote] Cylinder heads finished, no problem at all, very pleased. Basically a repeat of the 1-2-3 procedure from a few weeks ago. Another job off the list. While the heads are broken down, now was the time to perform my cylinder head volume measurements. I had a piece of thick perspex from years ago, doing the original CR checks, but it was a square piece made in a rush and needed rounding off. So I moved my belt sander outside and set up on the workbench (messy job, sunny day) and carefully sanded the Perspex into a circular disc that matched inside diameter of the cylinder head. This was working brilliantly, I just needed to drill another hole to let the air escape from the chamber whilst I was filling it with water. As you can see below I set up a rig to hold my new burette and had two attempts to fill the cylinder head chamber. The calculated volume this time was 87.7cc versus the calculation I did a few years ago using a stacked flame ring which gave me a volume of 90 cc. The G-clamp is just nipped up enough to seal the perspex to the head (with a layer of grease),not tightened enough to deflect the sheet concave, and alter results....in fact, fill #2 I did it without the cramp, so I could position the head with the air pocket uppermost.  So everything is going very well but it was time to pack up the tools outside. I went to carry the belt sander indoors, which was fine until I got within a foot of the workbench, at which point I must have twisted my left wrist in a way that it wasn’t supposed to go and the next thing I knew I was in excruciating pain. The sensation was very much like a dislocation combined with the trapped nerve sensation you feel when you’re back "goes". Apart from anything else it was actually quite scary and for 30 minutes I could barely move. I was quickly turning the air blue with some robust Anglo Saxon, turning a not-so-great shade of red and foaming like a rabid dog. Long story short, and after nine hours in our local hospital A&E department, a before-and-after x-ray showed that I had snapped off the top of my radius bone (the radial tip, which was previously "only" fractured), see the photo below.  (in the LH pic, the shadow at the radius of the bone was the original fracture, which I can't help feeling doesn't show the full extent of that first break. Spot the difference to the RH pic) Without a word of a lie it was an order of magnitude more painful then when I originally broke my elbow! I’m currently waiting until Tuesday afternoon when I see a specialist who focuses on elbows and shoulder injuries (not the same guy as last week! So much for his confidence in its strength), and it will be decided whether I need to have an operation to pin that bone back into place. Until then it’s a case of taking a concoction of painkilling tablets. That’ll teach me! I don’t think I’ll be able to do any more work for at least six weeks and at this point I ought not to be too adventurous. My arm really is now permanently in a sling, I dare not take it out. Arse. Last edited by Spenny_b; 09-01-2017 at 01:11 PM.. |
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09-01-2017, 01:07 PM
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Registered
Join Date: Mar 2005
Location: Phoenix, AZ
Posts: 2,854
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I hate this update.
Worst episode ever! When can we expect to return to our regular programming, i.e. reviews of trick little machined bits and forward progress? (Post *complete* healing)
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Chris Carroll TurboKraft, Inc. Tel. 480.969.0911 email: info@turbokraft.com http://www.facebook.com/TurboKraft - http://www.instagram.com/TurboKraft |
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09-01-2017, 01:12 PM
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Kartoffelkopf
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 Thinking back to when Lucy had to have her elbow pinned (this really isn't a weird family ritual...promise), she was in a cast for over 6wks, an operation before and after, then very light duties until the incision heals...call it 2-2.5 months. That takes me up to early/mid November. Yup, 2018 it is... |
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09-01-2017, 01:16 PM
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| Tags |
| 964 c4/c2/turbo , efi conversion , life racing , syvecs , turbokraft |
1993 Porsche 911 (964) Turbo 3.3
2006 Lotus Exige Cup 240 (#45 of 50)
BMW M2 Competition
BMW R1250 GS Rallye HP
Ducati 748R
930
Blackbird
1985 Porsche 930 Fac. Slantnose 3.3l
