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.

Nice job, buddy! :D

Thanks guys, keeping the car "looking" factory is pretty important to me and the 964 tail is really the only external mod that doesn't, but it's close when retracted.

Anybody have any comments about the transmission side cover that Thom was talking about?

Moses, drive south, left at LA, stop before you hit the mountains. If you find yourself in the desert you’ve gone too far. Come on over anytime.

Very nice Ryan! That interior looks sweet! I'd love to drop the coin to get mine redone. You have pots & pans, I have kids...you get off cheaper :)

How did that wheel bearing stuff work out?

Do you have an approx cost for the gauge faces? I'd like to do my tach.

I came across this at DC automotive. Would be a nice OEM touch...

Please let me know when the install party is!!

http://forums.pelicanparts.com/uploa...1065976724.jpg

Super! Thanks for all the great engine compartment pics, I am about to go there with my conversion using a Harald engine.

Now you did set the bar high on cleaning the engine though, damn! I've have to work more on that side of things...

Keep us informed!

Chris

Brad, that is cool. I don’t think it would work w/ my setup, do you have a pic of the back? I’m using a window switch w/ an auto controller that makes it one touch up/down. Anybody notice how the paint on the tail resembles the paint on Scruffy? It’s getting repainted though.

The engine came out really well but the pictures make it look even better than it is. I’ll post another update as I get closer.

For the non beer drinkers, how about some German wine?

http://forums.pelicanparts.com/uploa...1065995078.jpg

hallo
That switch is the Factory 993 Tail switch ,
Ryan , i was always wondering why it takes so long for the US-Airplanes
in Geilenkirchen to take off ,no wonder when they are loaded with Bit and Kellergeister .
Harald

The car is looking sweet. I like the switch for the tail. And all that booze must mean your going to invite all the pelicans over for a party.:D

Harald,

The Luftwaffe also has "long takeoff runs!" Everytime I see the 707 land in Washington Dulles its still heavy after flying all the way across the Atlantic. Lots of Bier und Wein for the troops based in the US!

Ryan, looks beautiful and if you have any trouble, invite Ingo and Mike over and it sure seems like they have the answers to any questions you might have on a 3.6 conversion! They helped me more in a few hours than the "guru" on the East coast has helped me in months!

JoeA

Let me guess, this all started with installing the 930S wheel and the rest is all "while you are in there"?

Looks great - really factory and clean.

Funny you mention that Harald. The last time I was over we had to spend a half hour burning fuel off so we could take off since we had so much beer on board. We don’t like those things to get out though, shhh. ;)

Joe, Ingo is becoming a regular at my house, and I live 2.5 hours away. I think he just likes that he always gets to leave w/ more parts for his car. Ingo, I have some wheel bearings that are in great shape, come on down!

John, actually I was changing the oil on the 3.0, and one thing led to another. :rolleyes: You know how these things can get away from you.

Ryan,

Are you on KC-10's or 135's? Spent a lot of time in the area, did medivac in that area years ago.

With Ingo helping you are in good shape. Good luck with it!

Joe

My wife & I are both on 135Rs; she is a pilot and I am a Crew Chief. Usually when we take more than one plane we both go, but I wanted to stay home this time and work on the conversion. I have had some great times over in Germany spending time driving through the country. It’s so neat that you can pull up to a Weingut’s house and their family will take you in and spend the day w/ you (even w/ the language barrier), drinking wine and teaching you what they do. I’ve met some great people in the world.

Ingo has been great helping me figure out what I needed to get for the conversion, and his wiring diagrams made it really easy to make my own conversion harness.

Harald was also great to send all the extra parts that I needed for the conversion. It's easy to do w/ out a kit once you know what you need.

Looks awesome, Ryan!

You're doing the kinds of things I dream about doing to my 2.7... :)

Ryan,

Remember it well. Brought loads of parts both ways (was based in Berlin for almost 10 years) and sounds like you are having a good time.

If you can, go to the Christmas markets in Germany this fall. Short train ride from where you guys base to several in the country. No where else like it in the world!

Joe

Ryan,

really nice work. I just put in your old overhauled starter when I finally had it with my tired one. I got stranded at a gas station Saturday morning and had to push-start me out of there.

It's night and day. It turns over soo much faster than my old 0.8HP one no matter if the engine is cold or hot. Yours is bigger than mine so I figure its the stronger version. I took the starter relay apart cleaned the contacts and lubed everything and it works like a swiss watch now. Guess I owe you more beer.

I hope you'll retire your entire suspension one day so I can get mine up to snuff.;)

Ingo (off to the land of the rising sun)

very sweet job you have going Ryan...it all looks great to include the fuse box! I need to do that with the inside of mine, very well organized.
You will be very glad you paid for all the tranny work...mine did not last long and I will end paying more in the long run.

Can we see some more pictures of the beer? ;)

yeah you guys are missing out (as I sit and drink a nice cold Hefeweizen) on the good stuff...but I am sure Ryan will share with the helpers if Ingo leaves any for them.

Hehehe...i think reason for that is that somebody sold them those pesky F-104G's that "happened" to need a lot more strip...

When I was based there in the 80's we had a joke.

How do you get your very own Lockheed F-104 Starfighter?

Buy a large piece of land in Germany and wait... it will happen eventually that one will be yours! I flew with 4 guys who flew the Starfighter. Two of them had to bail out at one time or the other...

Joe