3.6 Conversion Progress Update
 

Things are moving along now. I’ve had a few small stumbles but I think I have the game plan worked out and will hopefully be on the road early next month. I bought the engine from Harald in Germany and decided to do the conversion without a kit. I’ve also been hit hard w/ the “while your in there” syndrome. I’ve replaced a lot of parts and some of them have needed it and others I found out were perfectly fine. I’d much rather spend the money now just to be sure though.

The engine cleaned up very well. The only problem w/ it was some of the sheet metal was badly rusted; left side and front pieces. I bought a whole set that had already been modified to fit in an early chassis and was disappointed that it didn’t fit well. The holes for the lower spark plug wires were in a different spot and a few other differences. I thought about modifying it to fit but decided that it would be a compromise at best.

I went to Porsche and found that buying the pieces that I need would be about $1k for everything but the rear piece or $300 if I just replace the two really bad ones (ouch). I called Dr. Timmins and he said that he wouldn’t sell them to me b/c he saves them for his conversion customers (can’t blame him). I ended buying replacements for the two bad ones from Pelican for less that he dealer wanted.

First day, getting it out of the truck.
http://forums.pelicanparts.com/uploa...1065909970.jpg

I have the A/c bracket, valve covers, fan & housing, and chain covers at the powder coaters. I’ve replaced all the seals and gaskets that are accessible and am replacing components like the distributor cap & rotor, plugs, cylinder temp sensor, & oil temp sender.

Here she is all cleaned up.
http://forums.pelicanparts.com/uploa...1065909980.jpg
http://forums.pelicanparts.com/uploa...1065909990.jpg
http://forums.pelicanparts.com/uploa...1065910000.jpg

This pic shows the two brackets I made, one for the vacuum accumulator (I couldn’t bring myself to zip tie it) and the other for the intake.
http://forums.pelicanparts.com/uploa...1065910013.jpg

Tyson at TRE rebuilt the stock transmission w/ limited slip for me. He installed fittings for the transmission cooler that I will be installing at a later date. Here is a pic of the one piece bearing retainer that he installed in it.
http://forums.pelicanparts.com/uploa...1065910128.jpg

Here is a little chassis prep; the Appbiz engine pad, and the engine compartment electrical box (home made inner panel) & coils.
http://forums.pelicanparts.com/uploa...1065910138.jpg http://forums.pelicanparts.com/uploa...1065910147.jpg

I removed the entire interior except the dash. The seats and new RSA door panels (Appbiz) were recovered in leather. All new carpets were made in German wool and all the insulation was removed.
http://forums.pelicanparts.com/uploa...1065910158.jpg http://forums.pelicanparts.com/uploa...1065910166.jpg

The rear panels were modified a little for the DME harness to fit but I think it turned out really well.
http://forums.pelicanparts.com/uploa...1065910259.jpg

The Speedometer was refaced and recalibrated to 180mph, and the odometer was (mistakenly) set to 50. The Tachometer was also refaced and recalibrated so that redline would be at the top and the redline was set (mistakenly by me) to 7300 rpm. The alarm light was relocated to the dash and the O2 sensor light was wired as the check engine light.
http://forums.pelicanparts.com/uploa...1065910269.jpg

New trunk carpet (Appbiz).
http://forums.pelicanparts.com/uploa...1065910278.jpg

I am installing a C2 tail and retractable spoiler. Here is the switch that is located under the drivers seat, one touch up/down.
http://forums.pelicanparts.com/uploa...1065910297.jpg
http://forums.pelicanparts.com/uploa...1065910308.jpg

I’ve also replaced all the wheel bearings front/rear and am replacing all the CV joints. I’m sure I will have more questions, as I get closer to installing the engine. Here’s a pic of how I’m getting the guys over to help w/ the install.
http://forums.pelicanparts.com/uploa...1065910317.jpg

12 cases of German beer that my wife Kristy just brought back from a trip over there.

holy crap :eek:

and I mean that in a good way

Crap is right!

BTW, please don't ask me to total up the cost of all this, I'm not ready to go there yet, but I think the cookware is now paid for. :D

hallo Ryan
Those green Bit-Cases are just enough for the electrics ( Ingo ) ,you know he is German and one of the toughest Guys on the Bottle .
I am very amazed how you guys clean the Engines , and nice job on the Fusebox too.
Looks like you are almost there . have Fun
Harald

Thanks Harald, Ingo didn't make it down the day I did the wiring b/c he was too hung over, go figure.

I still have plans for him to earn his beer though.

Hey Ryan: what'd Tyson do to your transmission, other than rebuild it? Did he do anything to strengthen it?

He replaced a ton of parts, $2100 worth. There were a lot parts that were “borderline”, they were replaced mostly b/c of the 3.6 conversion, but I probably would have wanted him to replace them even if I had kept the 3.0.

I have an aluminum case so it’s already pretty strong. The one piece bearing retainer was the only piece that was installed purely for strength. The LS was factory.

No, Tyson didn't mention it so I didn't have him do it. I’ve heard about the side plates but I’ve never actually heard of failure there or the circumstances surrounding it. I’m sure it’s happened, or they probably wouldn’t sell the parts for it, but under what conditions?

What do think, bad oversight on my part?

Very nice work!! :)

Holy Crap!

That motor is way too clean. You are way too organized, and that is WAY too much beer. (Where is Highland, CA, and how do I get there from here?)

Nice job & wow! You deserve it Ryan!

Ryan,
Very nice work.

Sherwood

Looks great. I can't wait for BBR4 to see it receding toward the horizon in front of me. :)

wow!!!!!!!!!!! GREAT WORK

Looking Good, Ryan
Your doing some very nice mods. I think I'm going to be visiting North Hollywood Speedo, I like that tac, with a little lower blood pressure of course. Good Post, you get an A :D

all very impressive Ryan!! looks like you will be able to wear white gloves for the install :)

Great job! I like the "factory" approach and appearance.