930 Engine rebuild update
 

I'm not setting the world on fire with this rebuild since I'm 22 months into it. I tend to get distracted easily with other projects and shiny things. I've got everything fit up on the installed engine and now it's ready to come back out for intercooler, exhaust, & A/C brackets, a final check of the fasteners, and the wiring.

Engine details:

3.4 JE pistons w/7.7:1 comp
Mahle fully finned cylinders
Pauter rods
Twin plug
Heads matched to Carrera intake
EBS perf valve job & springs
C2 cams
B&B header & custom muffler
K27HF2
Motec M600 ECU
M&W CDI and coils
Patrick flywheel
Clewett aluminum pulley
Custom 25 x 10 x 4.5 intercooler
Tial 46mm wastegate & blow off valve

http://forums.pelicanparts.com/uploa...1143397315.jpg

http://forums.pelicanparts.com/uploa...1143397335.jpg

Looks good, better warn your neighbors when you plan to turn the key!

I thought I'd start with the wildest exhaust I could stand and work from there. There's room for a bigger muffler if it's too much.

David, it looks GREAT! It is going to be well worth the wait. I just wish we had the technology to see the first run streamed online. I'd sign up for pay-per-view.

BTW, Magic how's your monster running...perhaps provide David with a bit more boost of encouragement to the finish line:)

Very nice! Looks awesome!

That straight through is going to be damn loud tho :eek:

Post a sound clip when you fire it up. Nice engine!

Won't be *too* loud.

What I have:

http://forums.pelicanparts.com/uploa...1143418367.jpg

That's nice!
The sound may not be too bad, a little muffler goes a long way with the 930. Exhaust looks great!

did you rebuild it yourself? mean looking engine:)

Craig, your exhaust inspired the small muffler choice :D

Diabolos, I did build it myself. The only items I farmed out were the valve job and crank balancing. I even machined the twin plug holes, but I don't think I'll do that again. I think my gray hair count doubled during the machining. ;)

Dave - Looks awesome man...I bet you can't believe that almost 2years of your life in the back of that car....well worth it....its beautiful and excellent attention to detail...your 500whp is definitely a dyno session away.

Keep us posted.

Yasin

awesome work, brother, post a sound clip of that crazy exhaust for us:)

Care to predict a completion date? I can't wait to get my doors blown off by a new turbo version of Black Beauty.

-TT

I've just about given up on completion dates (good thing I'm not getting paid for this), but I'd like to have it running in time for the Houston CART race in May. There's an autox exhibition there that I've been invited to, of course I can still race the 400hp Austin Healey Sprite if my car's not ready.

Nice stuff David, love that exhaust! I got a zort tube thrown in with my turbo and I WILL run it for as long as I can bear it or as long as I can get away with it for!

I've finally finished the engine wiring harness (it only took a couple hours, I don't know why I procrastinate so much?). Here are some pics of the engine with the intercooler off:


http://forums.pelicanparts.com/uploa...1150559944.jpg

http://forums.pelicanparts.com/uploa...1150559965.jpg

http://forums.pelicanparts.com/uploa...1150559989.jpg

http://forums.pelicanparts.com/uploa...1150560010.jpg

More pics with the fan and intercooler installed:

http://forums.pelicanparts.com/uploa...1150567554.jpg

http://forums.pelicanparts.com/uploa...1150567576.jpg

http://forums.pelicanparts.com/uploa...1150567599.jpg

http://forums.pelicanparts.com/uploa...1150567623.jpg

http://forums.pelicanparts.com/uploa...1150567644.jpg

Looking really nice, David. Can't wait to hear how it runs!

Worth every bit of the 2 years you've got in it. Looks great!

Nice David, I really like that intercooler support bracket:)

are you planning on giving us a teaser media clip?

nice stuff david! wheres that intercooler from?

Thanks for the encouragement. When I finally get this thing running and broken in I'll post some video clips. I just hope the acceleration meets my expectations.

The intercooler and all the other plumbing was fabricated by me and some welders from work. The machined parts are by me and unfortunately they look a lot more crude in person.

i think the acceleration will be fine David!

To keep me away from the political forum, I thought I post a quick update :)

My clutch started slipping a few (OK, several) months ago and I finally got around to changing it. I replaced the Centerforce, which I do NOT recommend, with a Kennedy stage 1. The Kennedy's a nice piece! We may get killed with the Porsche tax but at least we get nice stuff!

I thought about lowering 2nd, 3rd, & 4th gears while I was in there, but after looking at my 401K and investments, I decided not to :(

I did make a couple changes though. I bought a Clewett IAC stepper motor from another Pelican and installed it, thanks purplehaze! Hopefully it'll start and idle like a regular car and not require 5 minutes of warm up.

The throttle linkage never felt right presumably due to combining the Carrera intake with the 930 linkage. I clocked and rewelded the bell crank on the engine and the transmission to get the angles right so hopefully that fixed it.


PS: I keep meaning to get that video clip, but I got sidetracked when it was on the dyno. I hope to get it back on the dyno this winter for final tuning so hopefully I can get it then. It sounds really wicked though!!! Sort of like a big block V8.


http://forums.pelicanparts.com/uploa...1225757964.jpg


http://forums.pelicanparts.com/uploa...1225757988.jpg

Hey David,

Beautiful work. So where did you get your intake aluminum tubing? I've been trying to figure out how to move my air filter from the left rear wheelwell into the engine compartment since my rebuild. Yours looks great!

Best,
Mike

Thanks Mike! I bought all the aluminum and stainless tubing at www.burnsstainless.com

Beautiful work, David!

This is a better use of your time that debating in political forums.

Very clean, and clever placement of the air filter.

Is that a Burns muffler? I may go with 2 of those over the winter - so I hope you post a sound clip when running.

Keep going!

It's a Burns 3.5 ID x 4.5 OD x 12" long muffler. I may switch to a 3.5 ID x 6.5 OD x 17" long to keep my neighbors on my good side.

LOL..I just bought that same muffler from Burns (the 17" long one).

Yasin

Uh, oh. That doesn't sound promising. Do YOUR neighbors still speak with you Yasin?

Post some sound clips when you get it going please!

Cheers -