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930 rebuild – The revival of my mothballed project
Hi everyone,
My name is Costa and I love air cooled Porsches! Although I have been lurking around the Pelican forums...long before I owned one, I have never actually introduced myself, until now. http://forums.pelicanparts.com/uploa...1473018134.jpg Part 1 – How it all began (the 911 bug bit me) I remember the day as clearly as if it were yesterday. It was 1997 and we were in our 1st year of study of mechanical engineering. My mate Matthew owned an Alfa 33 and we had just walked in to see Dawie at Glenwood Motors (in Pretoria, South Africa). Dawie was Matthew’s trusted Alfa Romeo go-to guy. These visits were frequent, as any Alfisti can attest. But this visit turned out to be very different to any of our previous visits… There it was. A silver 930 was strapped down onto Dawie's rolling road dyno. It growled, spat flames and put down power unlike anything we had ever experienced before. The impression it made would last forever. The two curious youngsters eagerly watched on, while Brian White tweaked the K-Jetronic and repeated dyno run after dyno run, while monitoring his mechanical pressure gauges. Brian is a legend in the South African Porsche fraternity. That day, friendships were forged and a Porsche journey began. I have been blessed, over the years, with opportunities to work on some very special projects and to meet fantastic people. I would like to share with you some of the more memorable moments: |
The resonance charging inlet manifold
During my final year of study, I convinced Dawie to loan me a 2.5 V6 12valve engine from a GTV6. The Alfa engine formed the basis of my Thesis “Engine performance improvement with inlet air resonance charging”.
My Thesis Project involved: a) Computer simulation of the gas dynamics in internal combustion engines. b) Design and construction of a resonance charging inlet manifold. c) Comparison of theoretical performance of std manifold vs resonance manifold vs ITB. d) Back to back engine dyno testing of std inet manifold vs the resonance charging inlet manifold vs ITB. http://forums.pelicanparts.com/uploa...1473020126.jpg http://forums.pelicanparts.com/uploa...1473020155.jpg http://forums.pelicanparts.com/uploa...1473020182.jpg http://forums.pelicanparts.com/uploa...1473020207.jpg http://forums.pelicanparts.com/uploa...1473020222.jpg http://forums.pelicanparts.com/uploa...1473020246.jpg http://forums.pelicanparts.com/uploa...1473020265.jpg http://forums.pelicanparts.com/uploa...1473020284.jpg |
My Thesis project was a wonderful learning experience and it opened up the door to my first 911 project with Brian White (more about that project tomorrow).
For those of you that are interested in more details on my resonance charging project, you can read more in the thread http://forums.pelicanparts.com/porsche-911-technical-forum/914607-964-resonant-intake.html#post9124580 ....All good projects are accompanied by some drama: http://forums.pelicanparts.com/uploa...1473020922.jpg http://forums.pelicanparts.com/uploa...1473020940.jpg http://forums.pelicanparts.com/uploa...1473020958.jpg Disaster struck when the motor dropped an exhaust valve while mapping the EFI at around 5500RPM WOT! I remember 2001 was a busy year for me. Dawie was a super gentlemen and helped me rebuild the motor. I was back on the Superflow dyno within 2 weeks! |
Hi from Arizona.
I spent many great days with Dawie with my 1750 and 2000GTV Alfas. Also worked with Brian for a few years at NPI. Small world... Now working on building 930 Turbo track car with 996 daily driver. |
Hi Luis.
Yes indeed...very small world! Thank you for writing. |
Using a computer to predict engine performance
My university project brought me together with Neels van Niekerk, who wrote the software (EngMod4T) which was used for my project.
The good correlation on my project between the computer simulations and my dyno results piqued Brian’s interest and the next step was a no-brainer…. Next we tackled Brian’s very own 993 Supercup… and it was executed methodically the Brian White way. No shortcuts here! • His engine was measured up meticulously and all the dimensional parameters were entered into the computer model • My computer simulation was executed and validated against numerous previous engine configurations which Brian had extensively documented. • Only then did Brian “trust” the computer simulation enough for me to proceed with “what if we change this?” and “what if we change that?” What if we change them together?….etc etc. It is not every day, that you get the opportunity to play with a 993 cup engine. It is even more rare to convince Brian White to cut and change his ITB lengths and exhaust primaries and secondaries. It is priceless when you achieve significant improvements on an already competitive engine package! https://youtu.be/-kOr_C6jDUU https://youtu.be/oTkcO1WonP0 |
The '74 RSR Turbo
So Brian calls me up and tells me about Johan van Veelen and his RSR Turbo project….would I be interested to help out?
Um….YES! So my teeny tiny contribution to this awesome project was to design and provide the manufacturing drawings used to recreate the famous wing and NACA ducts. http://forums.pelicanparts.com/uploa...1473099659.jpg http://forums.pelicanparts.com/uploa...1473099716.jpg http://forums.pelicanparts.com/uploa...1473099685.jpg http://forums.pelicanparts.com/uploa...1473099994.jpg http://forums.pelicanparts.com/uploa...1473100016.jpg Brian White speaking to Johan van Veelen before he goes out (Zwartkops Raceway, Pretoria, South Africa) http://forums.pelicanparts.com/uploa...1473100062.jpg more pics here http://forums.pelicanparts.com/911-930-turbo-super-charging-forum/673936-mfi-turbo-engines-lot-pics.html#post6964781 |
Trust 956
Ring ring.
me: Hello Mr White. Costakis.....have you ever seen a 956? me: No. What is that? http://forums.pelicanparts.com/uploa...1473101759.jpg http://forums.pelicanparts.com/uploa...1473101780.jpg http://forums.pelicanparts.com/uploa...1473101808.jpg http://forums.pelicanparts.com/uploa...1473101889.jpg Siggi Brunn with Frans Pretorius (the new owner of the Trust 956) http://forums.pelicanparts.com/uploa...1473101930.jpg http://forums.pelicanparts.com/uploa...1473101991.jpg http://forums.pelicanparts.com/uploa...1473102083.jpg http://forums.pelicanparts.com/uploa...1473102112.jpg http://forums.pelicanparts.com/uploa...1473102172.jpg http://forums.pelicanparts.com/uploa...1473102200.jpg ...about to go out with Siggi. |
http://forums.pelicanparts.com/uploa...1473102723.jpg
That is the smile you have....after riding shotgun in a 956! Pinch me...I must be dreaming! Thank you Siggi. |
Aladdin's cave of Porsches (AKA Brunn Racing, Germany)
Ring ring.
me: Hello Mr White Costakis.....do you have plans for December? me: No. Why? Lets visit Siggi... http://forums.pelicanparts.com/uploa...1473103471.jpg http://forums.pelicanparts.com/uploa...1473103500.jpg http://forums.pelicanparts.com/uploa...1473103614.jpg http://forums.pelicanparts.com/uploa...1473103764.jpg http://forums.pelicanparts.com/uploa...1473103947.jpg http://forums.pelicanparts.com/uploa...1473104132.jpg http://forums.pelicanparts.com/uploa...1473104474.jpg http://forums.pelicanparts.com/uploa...1473104594.jpg http://forums.pelicanparts.com/uploa...1473104680.jpg http://forums.pelicanparts.com/uploa...1473104715.jpg |
http://forums.pelicanparts.com/uploa...1473105324.jpg
http://forums.pelicanparts.com/uploa...1473105350.jpg These photos were taken LONG before FB and twitter.......circa Nokia 6230 ;) It is needless to say that hundreds of photos were taken.....this is just a teeny sample. I wouldnt want to risk boring you.... |
what!.....Alladin has some more caves filled with Porsches?
Ing. August Deutsch and the 908/02-022 "Steve Mcqueen”
Ing. August Deutsch has owned Steve Mcqueen's 908 since 1974. Steve Mcqueen raced this 908 through 1970. It was also used as a camera car during the filming of Le Mans. http://forums.pelicanparts.com/uploa...1473108048.jpg Herr Deutsch (right) and Siggi (middle) http://forums.pelicanparts.com/uploa...1473108123.jpg http://forums.pelicanparts.com/uploa...1473108197.jpg http://forums.pelicanparts.com/uploa...1473108215.jpg http://forums.pelicanparts.com/uploa...1473108280.jpg http://forums.pelicanparts.com/uploa...1473108296.jpg |
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Part 2 - The fulfilment of a dream. My very own 930
I have bored you for long enough talking about other peoples Porsches.
Time to talk about my very own 930. To be continued tomorrow..... |
Lots of cool stuff, but what about your project? ;)
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You couldn't pay for a better education.Totally jealous.
Sent from my SM-N910T using Tapatalk |
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. |
So the dream was eventually fulfilled in 2007 ...... a good 10 years after seeing "that silver 930" on Dawie's dyno.
Stories of Good Times ..... told by pictures ... http://forums.pelicanparts.com/uploa...1473189828.jpg http://forums.pelicanparts.com/uploa...1473189866.jpg http://forums.pelicanparts.com/uploa...1473189901.jpg http://forums.pelicanparts.com/uploa...1473189936.jpg http://forums.pelicanparts.com/uploa...1473189976.jpg http://forums.pelicanparts.com/uploa...1473190005.jpg http://forums.pelicanparts.com/uploa...1473190044.jpg http://forums.pelicanparts.com/uploa...1473190086.jpg http://forums.pelicanparts.com/uploa...1473190118.jpg http://forums.pelicanparts.com/uploa...1473190144.jpg |
Part 3 - So what weng wong?
So happy days enjoying the car at track days, DE events, autocross, weekends away with the wife etc etc..
So what went wrong? In Dec 2009 I encountered some trouble during a track day at Kyalami. The car started making a trail of blue smoke while I was out on the track. The track marshals flagged me off to prevent spilling oil on the track. We inspected and the car wasn't dripping oil so I was allowed to proceed back to the pits. Once back in the pits, we did find some oil dripping on the ground. Long story short, one of the chain ramp posts came loose and fell into the engine. The oil was dripping out of the vacant hole in the LHS cam chain housing, onto the exhaust .... and the rest can be left to your imagination. http://forums.pelicanparts.com/911-engine-rebuilding-forum/699433-epoxy-really-2.html#post6957819 http://forums.pelicanparts.com/911-engine-rebuilding-forum/742412-timing-chain-housing-repair-replace-chain-ramp-pins.html#post7364608 Engine drop: http://forums.pelicanparts.com/porsche-911-technical-forum/401955-supporting-engine-removal-5.html#post6962011 http://forums.pelicanparts.com/porsche-911-technical-forum/608273-show-me-your-engine-removal-without-using-lift-shots-3.html#post6962038 http://forums.pelicanparts.com/uploa...1473192442.jpg http://forums.pelicanparts.com/uploa...1473191971.jpg http://forums.pelicanparts.com/uploa...1473192469.jpg http://forums.pelicanparts.com/uploa...1473192076.jpg http://forums.pelicanparts.com/uploa...1473192106.jpg http://forums.pelicanparts.com/uploa...1473192128.jpg Next: I will post pics of the engine tear down. To be continued tomorrow... |
Engine dissasembly
I worked through my photo archive and picked the following pics:
(Note - pics were taken in 2010!) http://forums.pelicanparts.com/uploa...1473272254.jpg http://forums.pelicanparts.com/uploa...1473272305.jpg http://forums.pelicanparts.com/uploa...1473272479.jpg Nothing unusual for the age. Normals level of grime for these engines. http://forums.pelicanparts.com/uploa...1473272649.jpg A bit of oil accumulated on the back of the inlet valves. http://forums.pelicanparts.com/uploa...1473272682.jpg Nice and dry in the exhausts. http://forums.pelicanparts.com/uploa...1473272718.jpg Rocker shafts nice and dry. http://forums.pelicanparts.com/uploa...1473272744.jpg http://forums.pelicanparts.com/uploa...1473272772.jpg http://forums.pelicanparts.com/uploa...1473272803.jpg 1st head off. http://forums.pelicanparts.com/uploa...1473272820.jpg 1st impression of the bore is very good. |
Special tool to help loosen the cyl head barrel nuts
... I too can confirm that the head nuts on these old 911s can be very stubborn to remove!
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: http://forums.pelicanparts.com/uploa...1473275493.jpg 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 |
...oh....and while you are in there....
....why don’t you have a go at freshening up the suspension?
http://forums.pelicanparts.com/uploa...1473277080.jpg |
Part 4 – The revival of my mothballed project!
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 |
Side note:
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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"! :rolleyes: |
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..... |
The time has come to complete my 930
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. |
What is my end goal?
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. |
Getting Help
The engine has been entrusted with the team at Café 9 Automotive.
The parts were gathered together........ http://forums.pelicanparts.com/uploa...1473364780.jpg http://forums.pelicanparts.com/uploa...1473364816.jpg http://forums.pelicanparts.com/uploa...1473364834.jpg http://forums.pelicanparts.com/uploa...1473364857.jpg http://forums.pelicanparts.com/uploa...1473364895.jpg http://forums.pelicanparts.com/uploa...1473364928.jpg http://forums.pelicanparts.com/uploa...1473364947.jpg http://forums.pelicanparts.com/uploa...1473364966.jpg http://forums.pelicanparts.com/uploa...1473365213.jpg |
....loaded into the car and dropped off at Café 9 Automotive.
http://forums.pelicanparts.com/uploa...1473365514.jpg http://forums.pelicanparts.com/uploa...1473365551.jpg |
Project Phase 1
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 http://forums.pelicanparts.com/uploa...1473366864.jpg http://forums.pelicanparts.com/uploa...1473366887.jpg http://forums.pelicanparts.com/uploa...1473366911.jpg http://forums.pelicanparts.com/uploa...1473367049.jpg http://forums.pelicanparts.com/uploa...1473367094.jpg http://forums.pelicanparts.com/uploa...1473367114.jpg http://forums.pelicanparts.com/uploa...1473367277.jpg http://forums.pelicanparts.com/uploa...1473367379.jpg http://forums.pelicanparts.com/uploa...1473367561.jpg |
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The "school fees" and the "learning" is always ongoing... |
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Very cool experiences. Post up some more pictures of that cute dog too.
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http://forums.pelicanparts.com/uploa...1473620650.jpg |
Project Phase 1 - hiccup!
....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. http://forums.pelicanparts.com/uploa...1473621398.jpg Good news - darn, gona have to fit that twinscroll GT35R sooner than I thought! :D |
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: http://forums.pelicanparts.com/uploa...1473622835.jpg |
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) |
What size cylinders? Are the heads chamfered for them? Hard to tell from the pic but it looks like a pretty large sealing surface?
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