SWB 911R...the beginning

[rvanderpyl]

I thought you were going to run the oil lines inside the rocker panels?

Nice work with all the progress

[Grady Clay]

Lars,

Looking good.

At your altitude, we need to run your fan 1.82:1 to the crankshaft. That will keep the important stuff (heads & cylinders) cool when running home on a hot afternoon.

We need to find you oil level and oil pressure “S” instruments. When doing this, add a oil pressure warning light that you can’t miss. Porsche didn’t have both until the late ‘70s.

Best,
Grady

[speedo]

I made all the oil lines. The hose and collars are from Chuck at Elephant Racing. I cut all the fittings from old oil lines and cleaned them up to reuse. I found a local hydraulic shop and had them re-crimped. You must be extremely precise in your measurement as the hose needs to be the exact length, and it doesn't rotate easily...so you need to orient the 90 degree fittings correctly before crimping. The advantage of reusing the old metric fittings is that I didn't need to use AN adapters, (the cooler needed a couple) and for the most part...kept everything metric throughout. These look nice....but each hose had it's own issues.An example...this is the line that comes out of the tank...goes into the longitudinal here

It comes out of the longitudinal here

I started with the old oil line and removed the 90 degree fitting
This line needs to be flexible, so the line I use is high temp-oil resistant-high pressure line. The ID is slightly larger than the OD of my fitting. I needed to bring the OD up to 1" so I slide a piece of steel tube over the fitting
weld it up and run a light bead around the circumference which I will shape to a "barb"

And fit
This was the only pressure line where I needed to use flexible tubing as this connects with the metric fitting that goes through the engine mounted oil cooler. All the other lines I used the Smart Racing lines and crimped to the old re-used fittings

I also used this non braided line for the breather lines coming from the thermostat console to the oil tank...and then back to the console. It is tight up there! The missing line is the one that is mounted to the engine and comes out of the scavenge, and routes up to the thermostat.
That will get installed in a couple weeks when the engine bolts up.

[Duckworth]

...Being a bit outta touch with snapping and posting pics - I was actually under the impression that these pics were being snapped and posted at maybe 5 sec per pic !

Kinda surprised to hear that they take - a minute per each one.

All that welding stuff a few months back.....gave me the impression of -hitting an arc, goggles off, snap a pic, post the pic.... in a few seconds lapse.

Hope the resolution idea does the trick.
Very nice pics all round..
______________

'82 Targa
'80 928

[gsmith660]

You got a hose that looks like its all kinked up.

[Grady Clay]

Lars,

Pelican gsmith660 is correct. That hose has a ‘twist kink’ (yellow arrow) and will soon fail.





Porsche Factory can have custom hose assemblies made with the 90º fittings pointing the correct direction. Us mortals need to always have at least one end of a hose assembly with a straight fitting. This allows the hose to not have a built in twist. When assembling a system, the straight fitting is last to be tightened so the hose can ‘relax’ to a no-stress’ position.

The same is true for length. The design must allow for the hose to assume a natural, ‘no stress’ position. This is usually accomplished by having a bend that allows for any difference in length.

Best,
Grady

[DW SD]

Grady,
Cannot the hoses be indexed upfront to ensure their relaxed state? Before going a different route, I had planned to install the hoses and ends and then hose clamp each end in place. From there, I was to send them off to Chuck or another source for swaging.

Doug

[Larrybrook]

I wasn't sure if anyone would get the Rocky Horror Picture Show connection...nicely done! This forum is especially informative to someone like me who only grew up on relatively simple - North American cars. Thanks to all who post here!

Now for the blasphemy...how much pressure is in these oil lines? If twisting is a problem, could SPEEDO simply cut the new line and install a union or a short section of barbed pipe with hose clamps? It might not be aesthetically pleasing but if it helps to remove stress and prevent future failure…

Also look at the photo; will the fender cause a pinch point on the one oil lines? Can they be "stacked" vertically to get away from the fender?

[Grady Clay]

" ...how much pressure is in these oil lines?"

The pressure relief valve in the oil filter console that Lars is using (’72 only) opens at about 100 psi. Bruce Anderson and I agree on this but Porsche never published a spec as far as we can tell. The same valve is used in the 911SC thermostat/relief valve assembly. Similar pressure relief for the ’69-’71 911S separate relief valve as is the race part common to RSRs and 935s among others.

The ’73 911S and Carrera RS do not have a pressure relief valve. They only used the ‘trombone’ pipe ‘cooler’ which can withstand several hundreds psi. If you install a real cooler on those cars, you need to add a pressure relief valve.

The usual situation where the system sees high pressures and the pressure relief valve is necessary is on cold start up. This is particularly true when the 911 is parked hot and let sit for some period. When started cold the scavenge pump is pushing pure (solid) oil, not the 40/60 air/oil mix of normal running. This can overpressure a cold system without a pressure relief.

Best,
Grady

[speedo]

I had wanted to get the engine completed before diving back into the car. Engine is now complete except for the tall manifolds that are coming from PMO. I spent a lot of time cutting and fitting the clear shroud. While the fitment was good, there was a lot fof trimming that needed to be done. Before
During
I decided to bolt up the 40IDAs with the carbs just for the satisfaction factor even though I have to install the taller manifolds...the smaller ones will be for sale shortly. I also decided to run the plug wires. I measured the pulley ratios and came up with 1.64-1 which is less than Grady's suggestion, but more than stock. As this runs a big cooler up front and is a street car, I'm comfortable with that. And the new 2.7 RS engine waiting for SSIs to arrive...


Engine is just about done so I can move on.

[speedo]

I had a slightly miffed oil line that runs from the oil console to the oil tank ...this is used when the oil is cool enough not to cause the thermostat to shunt the oil up to the cooler
I sensed he was tense...so I loosened the fitting to the cooler and "relieved him"

I have two electronics consoles , both nasty looking.
While I am in the process of joing the original 912 engine compartment harness with the harness off the rs engine...I needed to clean up what I was working with
When I was building the engine, I revived the 2.7 harness and cleaned it up. I will "pin out" the necessary wires and create a new 14 pin connector. All the lighting wires for the cars rear end will be easy...it will be a little more complicated for the engine electronics.
I completely disassembled the steering column to lubricate and paint


The headliner had been hanging from the ceiling for two weeks to eliminate any creases and folds. I had been promising myself that I would attack it when the engine was done. Today was "no excuse day". I normally dread doing the headliner for several reasons...1) it sucks 2) to do it correctly and tension the headliner right takes two people...and there is only one of me...so it sucks more, andf 3) this headliner had the pockets for the 4 stays sewn just a little bit too close...so you would get the stays all lined up vertically ( if you have done this before, you know what I mean) and you would try to straighten the 4th one and they would all collapse to the direction you were tensioning. I'll quit complaining. In the process..
further along...by the way, I use a great contact cement called "Barqs"...great fumes
Andf when I woke up, it was done

For reference, The first time I did a headliner, I had to spread it over a couple days. The second time, it took about 8 hours, and this time I got it down to about 4 hours...getting better.

[gsmith660]

Originally Posted by Larrybrook

I wasn't sure if anyone would get the Rocky Horror Picture Show connection...nicely done! This forum is especially informative to someone like me who only grew up on relatively simple - North American cars. Thanks to all who post here!

Now for the blasphemy...how much pressure is in these oil lines? If twisting is a problem, could SPEEDO simply cut the new line and install a union or a short section of barbed pipe with hose clamps? It might not be aesthetically pleasing but if it helps to remove stress and prevent future failure…

Also look at the photo; will the fender cause a pinch point on the one oil lines? Can they be "stacked" vertically to get away from the fender?

That hose looks a little tight and maybe crimped when you drive that will cut through pretty quick unless thats kevlar then it will take a little longer

[speedo]

But unfortunately found that there is a difference in the rubber trim rings between 65-69 and later
So, these won't fit in the dash, and I can't start to organize the front wiring. I did however get these back from being chromed. I'm glad I decided not to go with the brushed aluminum look...

My PMO taller manifolds showed up and now I can swap out the early manifolds for these

I coerced a friend to help me look over the 901 trannie I wanted to run with the 2.7 RS engine. I wanted the shorter AFMSX gearing. We found that the first gear dogs were gone...but fortunately, the donor
Had a nice first gear set, so we swapped out the worn for the nice. The reality was that the daylight had gone, temperature at 8100 ft had dropped close to freezing and we were fighting the cold using a trouble light to get it done. The carnage
And the fresh trannie
This guy knows his trannies...if anyone needs gears/parts (early or late) or a trannie "freshened", PM me and I will provide contact info.

Thanks Matt

[RWebb]

what's wrong with the trim rings? you mean the chrome ones, right?

are they too small?

[speedo]

Maybe I mispoke...they are not trim, they are the rubber seals that go over the outside of each instrument. They help hold the instrument in place in the dash opening and due to the fact that they are rubber, probably provide a small degree of cushioning. The point was that while we can mix and match instruments , the seals are specific to certain years...in my case I need pre 1969 seals as the 1970 and later are apparently too thick. I guess I could wrap electrical tape around the outside of each instrument as an option, but I'll hold out for the correct seal.

[rvanderpyl]

I just used electrical tape, it worked fine, and you can't see it once it is in place.

[speedo]

I decided to use some rubber U channel I had in the shop and modify it. I could have used the electrical tape idea...but I wanted the rubber bead along the outside of the instruments bezels. The set are snug and the rubber bead is visible

I had to disassemble the shroud to open up the intake holes for the new PMO manifolds. The 2.7 manifold seats are not symmetrical...because the 2.7 heads are designed for CIS and the injectors come into the heads from the right side. It just took a while to massage the shroud to fit the heat insulators,gaskets and the new manifolds...done

I'll sort the front harness and start to wire up the instruments...install the wiper mechanism and washers. I am also sorting out the engine compartment electronics console...and making it accomodate my CDI,fuel filter,voltage regulator, and coil. I am working on both ends towards the middle. That means the carpet set needs to go in shortly...

[zotman72]

So is that funky KPH/hour speedo a new mandatory compliance regulation stipulated from the Peoples Republic of Boulder DMV? With that optimistic 10K tach, is it ok to miss shifts too? You did use new rod bolts I hope..... Awesome work as always, does this project have a completion date yet? That 912 I found you under your porch deserves better....

[Matt Monson]

I wish I moved as quickly on my projects as you do.

BTW, your tranny has A,F,M,S,Z in it. Remember, it had been rebuilt and regeared prior to you going in there.

[mikeferg75]

Lars, you have been busy!!! As always looks excellent.

See you Saturday?

Ferg