The IF2 thread

[Wrecked944]

Originally posted by beepbeep

Hmmm...I wonder what the story is on the blue Porsche in the background...

[81 930]

Hi Goran. That's one awesome car. I've been a fan of it ever since you posted some videos here a year or two ago.



What's the story behind the foggers on the intake manifold? Does it run nitrous? I also find it interesting that the secondary chamber in the intake manifold has been blocked. I am curious if the engine was dynoed with this chamber connected as well. The reason I ask is because I am planning to use a similar manifold on my 930 when I convert to EFI next year.

Cheers,

[Zeke]

A little OT, but I hate to think of what that body guy's ears, eyes and lungs are gonna be like in 20 years. Ask me how I know about these things.....

Well, my eyes are not full of holes and my lungs have healed, but my hearing..........WHAT??

[beepbeep]

Originally posted by 81 930
What's the story behind the foggers on the intake manifold? Does it run nitrous? I also find it interesting that the secondary chamber in the intake manifold has been blocked. I am curious if the engine was dynoed with this chamber connected as well. The reason I ask is because I am planning to use a similar manifold on my 930 when I convert to EFI next year.

Cheers,

It's a pic of old 3.6 intake configuration with NOS foggers. 3.6 intake was replaced with homebuilt one as it wasn't flowing good enough. All that V-Ram crap with dual chambers is just in a way when you turbocharge. NOS foggers were removed as well as engine makes enough power without them.

New intake:

[81 930]

Very nice! Thanks for sharing the pics.

[beepbeep]

OK, Björn opened the engine.

1. oil-scrapper rings are shot (1mm gap in cylinder), to be changed.
2. rockers are shot and to be swapped for roller-rockers.
3. crank (GT3 Cup) has spun one bearing and is to be reground and fitted with oversize bearings.
4. One rod is shot and is to be changed.

This is quite weird, as engine had less than 5 hours of runtime and it looks like it run 140kmiles.

Experts say wrong oil viscosity was used.

One thing is for sure, it had oiling problems. Oil pump was changed to bigger one and oil-pressure was never stabilized.

[PorscheGuy79]

Originally posted by beepbeep
OK, Björn opened the engine.

1. oil-scrapper rings are shot (1mm gap in cylinder), to be changed.
2. rockers are shot and to be swapped for roller-rockers.
3. crank (GT3 Cup) has spun one bearing and is to be reground and fitted with oversize bearings.
4. One rod is shot and is to be changed.

This is quite weird, as engine had less than 5 hours of runtime and it looks like it run 140kmiles.

Experts say wrong oil viscosity was used.

One thing is for sure, it had oiling problems. Oil pump was changed to bigger one and oil-pressure was never stabilized.

Arnt you supposed to gently break them in before flogging the piss outta them? Could that have been the problem?

[beepbeep]

Couple of new pics from dismantled engine:

One rod bearing spun and gouged GT3 crank quite bad. Rod was also scratched somewhat but it could be polished.





Whole crank is turned down to next OD and OD bearings were used on all rods. I find this quite risky as there are many steps to be done but shop that did the job believe it will work (new crank is $$$).

Also, rocker bushings were in very sorry state. one of them was really worn down. Engine builder used 993 rockers (which use hydraulic valve adjustment) and modified them by welding the oil chanell shut and drilling two holes on sides so that bushing can be lubricated by oil splashing from the cams. unfortunately, that wasn't enough and resulting steel-to-steel contact damaged the pins quite bad.

New rocker-pins are installed and brass bushing are pressed in rockers. It will hopefully lead to less wear.





Pistons are in amazingly good condition, considering power levels and all abuse. There ae no ping-induced erosion or broken ring lands. Oil-rings are worn down though. Piston bolts (sp?) were worn and are replaced, toghether with all piston rings. All in all, just minor scratches on pistons skirts, probably from all dirt that entered the engine when air-intake tubes failed.

[89turbocabmike]

Thanks for the updates Goran, a very cool project and interesting to see the damage.

[beepbeep]

Few new pics:

New oil cooler is to be installed tilted forwards. Air is evacuated trough openings in hood.





Rain gutters are removed as well:

[beepbeep]

Oil tank is to be fitted up front, so smuggler box was widened somewhat:





Oil tank is quite hot, so reinforced bucket is welded around it to shield coupé from heat and protect the occupants in case of rupture:







Transmission tunnel is cut up so we can weld in new tubes to draw fuel/oil/linkage/brake lines trough:

[sand_man]

I like the "new version" much better!

[beepbeep]

Few new pics.

Car has been widened further, both front and rear:




A template (so CF roof can be moulded) has been made from original roof:


...which was then chopped off (car had sun-roof and it weighted a lot) :

[beepbeep]

Engine shroud has been moulded in carbon-fibre. Unfortunately, guy who made it used old (somewhat warped) shroud as template so new CF one was also warped . It took me few hours with dremel and drill to make it fit on engine. Looks pretty cool though and weights nothing.




Comming next:

New (better) intercooler, new improved plenum chambers with velocity-stacks, whole front and rear replaced with carbon-fibre flip-front.

[ChrisBennet]

Your posts are such a treat. Thanks for sharing Goran!
-Chris

[Glasgow 911SC]

Outstanding!

[Par911]

Another amazing project Goran, thanks for the photos and write up!! I guess HP Junkies isn't dead after all .

[YermanCars]

Great Fabrication

[beepbeep]

Originally posted by Par911
Another amazing project Goran, thanks for the photos and write up!! I guess HP Junkies isn't dead after all .

Cough...when I'm allowed to post dyno graph you'll see they are alive and kicking

Here's graph w/o figures:

Right now it's not power that's a problem but time to put everything together. We are going to Nürburgring in may and car has to be 100% dependable before Scuderia Hanseat...

(Un)fortunately, other guys in the team decided to re-design almost everything.

New plenum, new intercooler, gearbox cooler, separate watercooled turbo cooling circuit, new wire loom, carbon fibre flip-front, widened front suspension, carbon-fibre roof, new roll-cage, adjustable brake bias, new shifter mechanism etc etc.

We can pull it off purely knowledge-wise but time ticks buy and there are lot's of snags on the way.

[beepbeep]

This is new intercooler design. Instead of one big IC with twin inputs we are running twin intercoolers and twin throttle bodies with balancing pipe in-between. Old IC had sub-optimal air connection and old style turbulator cells. New ones are best that can be made:



After looking at pictures of Porsche race engines (mostly at pics of dismantled 962 engine in engine rebuild forum), we decided to use longer plenum runners to help off-boost torque at lower revs. They are impossible to install vertically due to space constraints so they are to be installed somewhat bent to the side:



New CNC-milled intake stubs, phenoilic spacers are thrown away:


Intercoolers might be hard to find space for:




FIA-classed fuel-cell and oil tank is installed: