930 rebuild – The revival of my mothballed project

[Costa P]

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.






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:

[Costa P]

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.

[Costa P]

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 964 Resonant Intake

....All good projects are accompanied by some drama:







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!

[Luislang]

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.

[Costa P]

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

[Costa P]

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

[Costa P]

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.










Brian White speaking to Johan van Veelen before he goes out
(Zwartkops Raceway, Pretoria, South Africa)




more pics here MFI Turbo Engines - Lot of pics

[Costa P]

Ring ring.
me: Hello Mr White.
Costakis.....have you ever seen a 956?
me: No. What is that?








Siggi Brunn with Frans Pretorius (the new owner of the Trust 956)












...about to go out with Siggi.

[Costa P]

That is the smile you have....after riding shotgun in a 956!

Pinch me...I must be dreaming!
Thank you Siggi.

[Costa P]

Ring ring.
me: Hello Mr White
Costakis.....do you have plans for December?
me: No. Why?
Lets visit Siggi...

[Costa P]

[Costa P]

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....

[Costa P]

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.


Herr Deutsch (right) and Siggi (middle)

[Costa P]

Roitmayer GmbH








Dinner with Herr Roitmayer

[Costa P]

I have bored you for long enough talking about other peoples Porsches.

Time to talk about my very own 930.
To be continued tomorrow.....

[Flieger]

Lots of cool stuff, but what about your project?

[kevin930t]

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

Sent from my SM-N910T using Tapatalk

[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.

[Costa P]

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 ...

[Costa P]

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.

Epoxy... Really??

Timing Chain Housing - Repair or Replace Chain Ramp Pins


Engine drop:

supporting engine at removal

Show me your engine removal without using a lift shots...
















Next: I will post pics of the engine tear down.
To be continued tomorrow...