WOW - 8 months since the last update - sorry guys.

After I got the motor in I wasn't really happy with the turbo location - it looked like I would have to relocate the oil tank and the headers were too low for the ride height that I was planning to run.

http://forums.pelicanparts.com/uploa...1290310262.jpg

http://forums.pelicanparts.com/uploa...1290310367.jpg

So after a long some deliberation I decided to go the real RSR direction and relocate the turbos to the rear. After a little CAD work I decided on the actual location and fabricated a new rear engine cross brace to hang the turbo's and allow the fresh air plumbing to route into the engine compartment.

http://forums.pelicanparts.com/uploa...1290311109.jpg

http://forums.pelicanparts.com/uploa...1290311213.jpg

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I then fabricated the fresh air pipework to the inter-cooler

http://forums.pelicanparts.com/uploa...1290311630.jpg

http://forums.pelicanparts.com/uploa...1290311660.jpg

And showing how it fits into the car.

http://forums.pelicanparts.com/uploa...1290311779.jpg

http://forums.pelicanparts.com/uploa...1290311831.jpg

Once I had the location of the turbo's and inlet plumbing finalized I decided on a set of Rarely8 equal length headers to connect all of the exhaust plumbing.

http://forums.pelicanparts.com/uploa...1290312455.jpg

http://forums.pelicanparts.com/uploa...1290312531.jpg

http://forums.pelicanparts.com/uploa...1290312569.jpg

The headers are exceptional pieces of work and the fit was perfect.

one of the best threads I have seen in awhile, NICE.

In order to get access to the front of the inter-cooler and to provide clearance for the large cast alloy inlet bend, I had to cut and access hole in the rear parcel shelf. I fabricated a frame, welded it in place and made an aluminum cover to match the cover over the transmission. You can see it at the top on the engine bay.

http://forums.pelicanparts.com/uploa...1290314021.jpg

Another "while-your-your-in-there" moment was the decision to strip and paint the engine bay. Epoxy primer and 2 pack topcoat.

http://forums.pelicanparts.com/uploa...1290313736.jpg

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As the rear end work was overtaking the front end work (its never good to have the rear end pass the front end) - I got stuck into finishing the front trunk, following the suspension pan replacement.

http://forums.pelicanparts.com/uploa...1290314754.jpg

http://forums.pelicanparts.com/uploa...1290314821.jpg

After I had painted the front trunk the OEM fuse box looked like it also needed some attention.

http://forums.pelicanparts.com/uploa...1290315108.jpg

So I decided to tidy it up and fit some more modern fuse holders.

http://forums.pelicanparts.com/uploa...1290315214.jpg

I decided to mount the fuel filter in the front trunk just after the in-tank pump.

http://forums.pelicanparts.com/uploa...1290315549.jpg

http://forums.pelicanparts.com/uploa...1290315610.jpg

With the fuel cell and vent plumbing installed.

http://forums.pelicanparts.com/uploa...1290315744.jpg

http://forums.pelicanparts.com/uploa...1290315842.jpg

One thing you may also notice from the 2 shots above - I installed the original Porsche fuel level sender into the fuel cell. The cell came equipped with a GM sender that wasn't going to work with the OEM gauge. I had to shorten the Porsche sender by about 12mm - it worked like a charm.

Looking good mot

I assume ur running dual zorks, or are u gonna run an X-pipe style muffler?

Thanks mjshira and juicersr.

Current direction is to run dual 3" zorks - I think the neighbors are going to hate me.:D

EXCELLENT! Just wouldnt be right any other way.

BTW, if Gabe's car is any indication, twin zorks at idle and part throttle are not as loud as your would think. My single Zork is a Helluva lot louder.

While finishing up the front trunk I wasn't all that happy with hood lock or the fuel filller in the trunk. So I installed a set of keyed hood locks that i had lying around in the garage.

http://forums.pelicanparts.com/uploa...1290317258.jpg
http://forums.pelicanparts.com/uploa...1290318346.jpg

The previous owner had removed the fender fuel fill door when doing the RSR conversion therefore I had no other option - go thru the hood.

This part was a little nerve racking (sorry about the dust, it shows how long it has been sitting in the garage :(
http://forums.pelicanparts.com/uploa...1290318505.jpg

5" Hole saw straight though the fibreglass hood. Didnt even chip the paint.
http://forums.pelicanparts.com/uploa...1290318603.jpg

Using a filler cap / tube kit sourced from Merek in DENMARK - this is a first class kit, supplied with all the parts needed to do an install including the overflow bowl and the seal for the underside of the hood. I modified the filler tube, to center the filler in the hood as the fuel cell was slightly off center and I fabricated the flange to bolt to the fuel cell.

http://forums.pelicanparts.com/uploa...1290318880.jpg

And finally with the hood closed - it all lined up pretty good.
http://forums.pelicanparts.com/uploa...1290318937.jpg
http://forums.pelicanparts.com/uploa...1290319630.jpg

This is really inspiring.

BTW, where did you get the injector blocks?

Mot, the 100mm Blau is perfect touch. I did the hole saw thing on my RSR off to the side, and it was nerve racking even on an unpainted hood.

http://forums.pelicanparts.com/uploa...1290349352.jpg

Do you have a link to the Merek kit by chance?

Do you have some close ups of how your hood pins hook into the body? Pretty trick, never seen those style before

Hi Richard

I am so glad you like the filler kit
Funny thing is I sold over 70 of these and your car is the first I see it on
just sitting in cold Scandinavia and surfing the web, that really warms my heart
to see your work

sorry If i do a small advert

Here is a link if anybody shold be interest in the filler kit

true the hood filar kit

Keep up the good work Richard and all the best

Regards

MAREK FROM DENMARK / COPENHAGEN SmileWavy

Really like that you changed out to the more modern blade style fuses.
I've often thought about doing that while refreshing the electrical (wiring) system.

Definitely need some sound clips when you get that engine running.
Everything looks super!

Thanks for all of the encouragement guys.

DV 933tt - the injector blocks and fuel rails were made by Billet Design in Florida. I match ported them to the manifold, just to finish them off.
http://forums.pelicanparts.com/uploa...1290359361.jpg

http://forums.pelicanparts.com/uploa...1290359417.jpg

This shot shows with one injector fitted.
http://forums.pelicanparts.com/uploa...1290361878.jpg


juicersr - I know what you mean regarding taking to the hood with the hole saw- it’s like pruning a flower bed with a chainsaw. I drilled a "plug" out of a piece of fiberboard first (hole saw through the fiberboard and then use the inside "wheel" to make a plug) and bolted the plug to the hood. This gave me a really steady guide for the hole saw as I didn’t want to trust the 1/4" pilot drill. I was worried about chipping the paint and the gelcoat but one of my friends who build boats suggested running the hole saw in reverse to cut through the paint / gelcoat - it worked really well.
Here are a few close ups.

http://forums.pelicanparts.com/uploa...1290359934.jpg

http://forums.pelicanparts.com/uploa...1290360009.jpg

http://forums.pelicanparts.com/uploa...1290360075.jpg

I brought the hood pins / locks from an auto store when I was living in New Zealand. They are "Speco" brand. They were reasonably priced and I used a set in my old RSR in NZ. They worked well so I brought another few sets just to have as spares. I never thought that I would be finally using them in the USA....
http://forums.pelicanparts.com/uploa...1290361372.jpg

I had to fabricate the brackets to hold the adjustable pins - as they needed to go lower in the front panel. I bolted them to give me a little adjustability and will tack weld them once I am happy with the location.
http://forums.pelicanparts.com/uploa...1290361446.jpg

http://forums.pelicanparts.com/uploa...1290361497.jpg



Merek - I am a little fussy when it comes to workmanship and IMHO your kit is absolutely stunning. The craftsmanship with the spun overflow bowl, filler tube and cap is first class. I am surprised that you have only sold 70 kits.
Also apoligiizes for the mistake on location, I corrected my error. http://forums.pelicanparts.com/suppo...leys/blush.gif

skinnerd - I also removed all of the harnesses that were not being used (air cond. fog lights etc. etc.) you would be really surprised how much extra wiring is in these things. It also really cleaned up the trunk area

Marek, thanks!!!SmileWavy

Those look great mot. Very clean. i have two cars now with the traditional pins, one with 'bobby pin' style, one with ring clip style, and both are a little fiddly. These have the added benefit of being lockable for front storage on road trips.

Awesome attention to detail! When will your engine fire up for the first time?
did I miss the transmission that you are running?
Really really impressive!
Never seen those 90 degree connectors for the corrugated wiring harness tubing. Where did you buy those?


Doug

With that support bracketry you show for the turbos and such....do you still have room to run the Carrera-style oil fed tensioner lines vertically down into the chain-cover case ??? Then again...the raised boss on the cam chain front cover don't seem to be drilled for these. Maybe you are not running hydraulic tensioners. Maybe you mentioned that elsewhere in this thread...but I missed it.

Hey bro - twin zorks ain't that loud at all.

Over the top build!


Would love to see someone put the throttle bodies at the injector blocks with the plastic 3.6 manifold above them for better throttle response. Seems like a lot of volume between the stock TB location and the intake ports to have to pressurize with acceleration.

With ITB's it would already be pressurized.

I guy can dream.