930 rebuild – The revival of my mothballed project

[Costa P]

I worked through my photo archive and picked the following pics:
(Note - pics were taken in 2010!)






Nothing unusual for the age. Normals level of grime for these engines.



A bit of oil accumulated on the back of the inlet valves.



Nice and dry in the exhausts.



Rocker shafts nice and dry.







1st head off.



1st impression of the bore is very good.

[Costa P]

... I too can confirm that the head nuts on these old 911s can be very stubborn to remove!

• add heat - check
• use a good qualty allen key socket - check
• give it a sharp blow to help "shock" it loose - check

Most of them came loose with the above procedure.....but what do you do with the few that refuse to budge and the barrel nut stretches and the allen key starts to slip?

I came up with the following special tool:


Start with a 12mm allen key socket.
Shape the six sides down in a taper (equal amounts) to end up with a tip that measures 10mm

You can drive the tapered tip into the already damaged barrel nuts (the blow also helps to loosen them).
This provided enough bite to turn them loose, combined with more heat (off course) + a pneumatic impact wrench

[Costa P]

....why don’t you have a go at freshening up the suspension?

[Costa P]

OK.
We are almost in 2017.
Almost 20 years have passed since "that silver 930"!
Almost 10 years have passed since I bought my own 930!
...and my car has been standing since 2010!




How did I arrive here?
(a moment to reflect)

....to be continued tomorrow

[Costa P]

Originally Posted by Costa P

Hi Luis.
Yes indeed...very small world!
Thank you for writing.

Luislang, my humble apologies for butchering your nickname.

This afternoon, my friend Neels (we work together) pointed out to me that your nickname is lui-slang and not Luis Lang.

Neels had a good chuckle....and proceeded to explain it meant "python" (as in snake)......and that I had just called you "flea"!

[Costa P]

So....how did I arrive here?

I arrived here:
1) Because of choices I made.
2) Because life happens and over time priorities shift.
3) Because there are only 24 hours in a day and you need to choose how to spend each hour.

Yes, I miss my car.
Yes, I would rather be driving it....than have it standing.

Over the past few years, the Pelican forums have provided me with inspiration and motivation during the ups and downs.

Tom's Odyssey, Lincoln’s resurrection......, Spenny’s EFI conversion........
I have followed all these (and many others) and created a vision in my mind for my own project.....

[Costa P]

Realisation 1: Costa, you can't do everything yourself - GET HELP!

Realisation 2: My appetite (AKA wish list) has evolved and grown much larger than what I can realistically afford at this stage. The kid inside me remains wishful that these desires will eventually materialize. So, I have decided to break down my end goal into bite size (realistic) chunks and tackle the upgrades in phases.

[Costa P]

Single Turbo, full bay IC, EFI, reliable power, track day toy + street driveable. Hopefully 450-500hp.

Key Criteria
a) Have fun building my project.
b) Reliability must not be compromised.
c) Build quality must not be compromised.
d) Strategic "modernisation".
e) Execute each step "properly" and avoid doing things over.
f) Execute the upgrades in phases to ease project cash flow.
g) Enjoy driving the vehicle until the next upgrade phase.

[Costa P]

The engine has been entrusted with the team at Cafι 9 Automotive.

The parts were gathered together........

[Costa P]

....loaded into the car and dropped off at Cafι 9 Automotive.

[Costa P]

1) Build the bottom end right, without short cuts and never have to touch it again.
2) install EFI (don't waste money on K-Jet)
3) reuse existing bolt-ons for time being (exhaust, turbo, IC, etc.). Upgrade these items in stages, in the future, as and when $$$ budget allows.

Phase 1 status:
Crank checked, balanced and polished - done
New main bearings - done
New big end bearings - done
New IMS bearings - done
Rods balanced - done
Reuse Std P&C s - thumbs up from Cafe 9
New Goetze rings - done
ARP rod bolts - done
ARP head studs - done
New chains - done
New chain ramps - done
Chain ramp post repair - done
New valve guides - done
Inlet port machined to 38mm - done
930 flat manifold ports machined to 38mm - done
Machine heads for twin plug (while you are in there) - done
Machine heads for 993 knock sensor bridge - done
Flywheel modified with 60-2 - done
964 crank sensor - done
964 crank sensor bracket - done
modify crank case to reduce windage - done
relief cut cylinders for windage - done

[Costa P]

Originally Posted by Flieger

Lots of cool stuff, but what about your project?

I'm getting there slowly....

[Costa P]

Originally Posted by kevin930t

You couldn't pay for a better education.Totally jealous.

Sent from my SM-N910T using Tapatalk

Thank you Kevin.


The "school fees" and the "learning" is always ongoing...

[Costa P]

Originally Posted by jsveb

Wow! With this intro, I can't wait for the rest.

You are one lucky guy.

I remember reading about Brian White. He is quite an accomplished man.

Thank you Jesper.

[Cairo94507]

Very cool experiences. Post up some more pictures of that cute dog too.

[Costa P]

Originally Posted by Cairo94507

Very cool experiences. Post up some more pictures of that cute dog too.

Hi Cairo, the white pup is named Bella and the brindle is my boy Cino.

[Costa P]

....So my plan was to reuse many of the old bits (bolt ons) for phase 1, get it driving, and upgrade those later;

Bad news - my 3LDZ is knackered!
The guys at Cafe 9 inspected and pointed out a huge crack in the CHRA on the turbine side.



Good news - darn, gona have to fit that twinscroll GT35R sooner than I thought!

[Costa P]

Which implies:
a) time to fabricate the new exhaust for the twinscroll GT35R
b) need 2x Tial wastegates

The S/S TIG welding is something which I have geared up to do myself:

[Costa P]

The knackered 3LDZ means that I need to revaluate the scope for Phase 1 ...... in terms of budget.

I need to be $$$ sensible and decide which upgrades can be parked for later Phase 2 upgrades!

I’v been running various scenarios through by budget spreadsheet and my conundrum can be summarised as follows:

Phase 1

Scenario 1: EFI with only 6x COP (upgrade to 12x COP in Phase 2)

Scenario 2: EFI with my old distributor (upgrade to 12x COP in Phase 2)

Scenario 3: reuse K-Jet (upgrade to EFI in Phase 2)

Decisions, decisions....$$$...$$$

Is my anti K-Jetronic paranoia unjustified?
I have spent the last 4 years hyping myself up to convert to a modern EFI system.
(Motec M130, Haltech Elite 2500 or AEM Infinity)

What are your thoughts regarding reusing the K-Jetronic to get the car running again?
(inevitably.....Phase 2 will be a couple of years away)

[cgarr]

What size cylinders? Are the heads chamfered for them? Hard to tell from the pic but it looks like a pretty large sealing surface?