Time to install and cross my fingers

[txhokie4life]

I acquired an RSR Replica earlier this summer.
The race engine had pistons slapping according to the PO.

As I'm still somewhat of a novice track driver and have never
driven a rear wheel drive machine, I figured I would find an
intermediate engine and start from there.
I have a goal to make a PCA event here in Texas at the end of October.
Not there yet -- but close.

Picked up a used 964 engine from a fellow PCAer and
shipped it to my buddies shop. This would be my first
attempt at touching an air cooled engine.
With support from my mechanic buddy -- I dove in.



Pulled the intake system off, Distributor, Power Steering, exhaust. None of
which will be needed since we will either run without these or use
the equivalent from the race motor.

Did some leak down tests and showed that it needed some top end attention.
The valve guides were worn, but otherwise everything was in good condition.
The cylinder liners looked great -- still had the cross hatch.

While I had the heads cleaned up and rebuilt with new exhaust valves
and all the guides replaced, I did my best to clean the rest of the engine. Not
the easiest thing to do when you still have the bottom end assembled.

While I was on vacation -- the heads came back.
I took Wayne's book with me -- I'm sure I looked like an uber-geek to most on the beach -- but I had a lot more than margs and sun to absorb :-)



Beginning the reassembly. Taking my time and double/triple checking with the book



Working on the other half of the engine. Plug every hole my clumsy hands could drop something into!



Finished with the top end. Working on setting the timing.
I was going by Wayne's book -- he really needs to have a 964 supplement :-)
I think the 964 tensioner system looks to be easier than what is shown in the book for previous models.

Once you get the gist of things -- it seemed pretty straight forward.



Passed my leakdown tests -- so I think I put everything back together and timed it correctly. Finger's crossed!

Closing up the timing chain and valve covers. I'm hoping there
are no oil leaks, but I'm a realist. Since it's a track engine AND I cleaned
up the engine pretty well, I should be able to keep an eye on things and
have some access room to fix any mistakes here.



Using the intake, fuel injection and electronics from the race engine.



Throttle Bodies and linkage connected up, Fuel Injectors, Coil Paks, Clewett Pulley and Light Weight Flywheel installed


Tranny Mounted -- ready for install. Trivia: DMFW uses 68mm flywheel bolts,
the Light Weight flywheel uses 28mm. The bolts and a few other misc goodies were missing from the parts pile -- probably hiding at the PO's garage.
Dang -- cost us a week!



Had some help getting the tranny mounted -- but the rest of the work has been all mine.

Hope to get the assembly in the car here in the next week or so.
Chumps race this weekend had my time and resources diverted.

Excited and a nervous nellie at the same time.
How will the Motec play with the engine setup here?
What issues will I have to debug?
How many oil leaks will I have?

How many issues will I have with the rest of the car's components?

How do you test a track vehicle without a track? :-)........

Next few weeks should be interesting.......

Have to go Chump this weekend first.



Mike