WOW oh WOW - what a great build. makes me want to go out and buy a welder. Nice work.

This build is seriously out of hand. I love it!!!!!

Thanks again guys for all of the kind words.

juicersr - whilst the hood locks are not exactly "period correct" - I like the look because they are practically flush with the hood and as you noted they are lockable. I don't know if they are available here in the USA - this brand is fairly common in Australia and New Zealand.

DW SD - I was hoping to fire it up before the end of this summer :mad: but for various reasons the build is dragging on. My current plan is to have it running before the end of winter - most of the hard work is done, just a lot of assembly now.
For the transmission I have a G50/50 that has been shortened.
The conduit fittings are from Waytek. You can get them in all different configurations and sizes.

Wil - I'm planning on running hydraulic tensioners - I just haven't finished the internal part of the engine build yet. There is actually plenty of room between the engine mount, fresh air plumbing and the front of the engine - as shown in this photo.

http://forums.pelicanparts.com/uploa...1290479747.jpg

Reaper - I still haven't had the chance to hear your car yet - my laptop locks up every time I try, I dont think it can handle the power. Congrats on your build - you must be happiest guy around this forum. Go out and enjoy it - it wont take you too long to before you need more more HP. :D

911st - sounds like you are describing Reapers set-up. He went to the ITB dark-side.

Progress continues - albeit slow.

ZORK tubes - I recently fabbed up the zork tubes - it took a lot of time to get them symmetrical - Now I understand why they are not symmetrical on most RSR's
:mad:
http://forums.pelicanparts.com/uploa...1297579224.jpg

http://forums.pelicanparts.com/uploa...1297579324.jpg

http://forums.pelicanparts.com/uploa...1297579359.jpg

To position the zork's I had the engine in and out of the chassis several times. One challenge that I had was to find a way to close off the 2 existing cutouts in the rear fiberglass bumper - from the previous exhaust system as shown in the photo below.

http://forums.pelicanparts.com/uploa...1297579745.jpg

I considered fiberglassing them in and then cutting a new opening for the zork tubes - but I was looking for something a little more unique and functional (dissipate some of the heat from the turbos). After a fair amount of messing around I came up with an idea that achieved what I was after. The photos show the rear grill in raw steel - I plan to powder-coat it black.

http://forums.pelicanparts.com/uploa...1297580290.jpg

I still need to trim the length of the zork tubes - hopefully you get the idea.
http://forums.pelicanparts.com/uploa...1297580355.jpg

http://forums.pelicanparts.com/uploa...1297580386.jpg

http://forums.pelicanparts.com/uploa...1297580446.jpg

One part of the engine build that I have not been entirely happy with is the air filter system. Eventhough it looked and fitted OK (see previous post on 22 Nov 2010), I wasnt happy drawing in hot air from the engine compartment. As I had already delated the rear seat I figured pulling air in from the rear quarter windows made sense however ducting the cold air to the turbos, through a filter, was a problem without a cold air / filter box. That was until I came across the K&N Apollo air filter system. From the K&N wesite:
The Apollo is a universal "Cold Air Intake System". The Apollo's specially designed shape increases volumetric efficiency and is made of durable lightweight material for cooler air intake. The Apollo incorporates a K&N famous cotton gauze filter which is removable for periodic cleaning and provides the benefits of an open cone filter and standard air box in one unit. Heat build up is reduced which keeps the intake charge cool. Smooth internal features minimize air turbulence and maximize air flow.
http://forums.pelicanparts.com/uploa...1297582004.jpg

I was originally planning to mount the Apollo air filters in the engine compartment. However as these Apollo units looked so good I figured why not mount them in the back seat area, where everyone can see them :D. I first removed the rear quarter windows and made some new ones out of 1/8" scratch resistant acylic sheet and fitted some NACA ducts.

http://forums.pelicanparts.com/uploa...1297582512.jpg

I then fabricated some tubes out of exhaust tubing, flanges and plumbed it all together with some silicon tubes.
http://forums.pelicanparts.com/uploa...1297582591.jpg

http://forums.pelicanparts.com/uploa...1297582630.jpg

http://forums.pelicanparts.com/uploa...1297582680.jpg

The picture below shows the 2 openings into the engine compartment. I will use silicone aircraft duct / hose from these to the alloy tubes leading to the turbo inlets.
http://forums.pelicanparts.com/uploa...1297582718.jpg

Due to the shape of the air filter box I can fit a drain to take care of any water coming in thru the NACA ducts (just in case I ever get caught out in the rain). Mounting these in the back seat areas may carry some of the induction noise into the cabin :confused: but I figured I wasn't planning on listerning to the radio or the wife while driving anyway........

What a great thread this is ! Lovely car

Very, very nice work I am jealous!

Dude great progress! She's coming together, what's the time frame on completion?

As usual mot, great progress. That CAI is really trick!

Honestly, i think u will find dual zorks are not that much louder than a free flow exhaust. Just wait for your first drive.... once u hear that sound, which is pure, unadulterated old skool group 5, u will never want anything else.

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hey brother just a heads up that once the pipes heat up they will walk around on you and end up in different elevations and angles. On the 935's they ran tabs to try to prevent this and they did the job to an extent.

Did the same on the wastegates all around so they held their direction...

http://forums.pelicanparts.com/uploa...1297706400.jpg

http://forums.pelicanparts.com/uploa...1297706444.jpg

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Inconel :D

Thanks for all the encouragement guys SmileWavy

I am still hopeful to have it running this for this summer. Most of the bigger things are completed however there are still a lot of small "details" that take care of, including a lot of powder coating.

Reaper - my zorks are currently only held together by a series of tack welds. I will tig them together once I am happy with the orientation. I like the "tab" idea - easy and very effective.

One of the "details" that I have been working on is to finish off the COP set-up. I have spent way too much time trying to make this work and hope it will work out OK in the end. I am planning on running twin 997 COP's on each cylinder, fired by a series of CDI units. I decided on the 997 COP's for a number of reasons - they are Porsche parts, our host sells them, they don't have an in-built igniter (making them suitable for CDI) and they have a high power output (>50mJ).
To fit them to the engine I found a set of used 964 valve covers on ebay that I have been modifying to fit the 997 COP's. I made a set of alloy plates that will hold the COP's in position. Here are some pics.

Machining the valve cover openings on my old W&I mill:
http://forums.pelicanparts.com/uploa...1297744989.jpg

Machining the alloy COP plates:
http://forums.pelicanparts.com/uploa...1297745105.jpg

Some shots of one COP fitted
http://forums.pelicanparts.com/uploa...1297745240.jpg

http://forums.pelicanparts.com/uploa...1297745298.jpg

Richard.

Mot, very intrigued by the COP set-up. Are they for the most part more reliable as well as being simpler than traditional wire/coil pack systems? Is tuning any different than traditional crank fire and coil pack systems? I only know about COP from what i have read, but is the learning curve on making these work fairly straightforward? Also, what about expense... is it any less $$ than traditional EFI systems?

This build would be wild anywhere in the nation...but Iowa:eek:

Being from Iowa myself SmileWavy, it's odd to see a non-american much less a wild 911 RSR turbo...Excellent work!

JmuRiz -
http://forums.pelicanparts.com/uploa...1297823417.jpg
Iowa - it's actually becoming very diverse. I moved here with my wife and children about 3 years ago (originally from Australia) and the locals are still questioning why we moved here - they typically think we are either mad or in witness protection.
A little OT but following our first winter here in Iowa one of my friends sent me this - almost pissed my pants laughing at how true it was. By the time we survived our second winter, I wished he sent it to me before we decided to move.
Dear Diary: Iowa Winters:
Aug. 12 - Moved into our new home in Iowa. It is so beautiful here. The hills and river valleys are so picturesque. I have a beautiful old oak tree in my front yard. Can hardly wait to see the change in the seasons. This is truly God's Country.
Oct. 14 - Iowa is such a gorgeous place to live, one of the real special places on Earth. The leaves are turning a multitude of different colors. I love all of the shades of reds, oranges and yellows, they are so bright. I want to walk through all of the beautiful hills and spot some white tail deer. They are so graceful, certainly they must be the most peaceful creatures on Earth. This must be paradise.
Nov. 11 - Deer season opens this week. I can't imagine why anyone would want to shoot these elegant animals. They are the very symbol of peace and tranquility here in Iowa. I hope it snows soon. I love it here!
Dec. 2 - It snowed last night. I woke to the usual wonderful sight: everything covered in a beautiful blanket of white. The oak tree is magnificent. It looks like a postcard. We went out and swept the snow from the steps and driveway. The air is so crisp, clean and refreshing. We had a snowball fight. I won, and the snowplow came down the street. He must have gotten too close to the driveway because we had to go out and shovel the end of the driveway again. What a beautiful place. Nature in harmony. I love it here!
Dec. 12 - More snow last night. I love it! The plow did his cute little trick again. What a rascal. A winter wonderland. I love it here!
Dec. 19 - More snow - couldn't get out of the driveway to get to work in time. I'm exhausted from all of the shoveling. And that snowplow!
Dec. 21 - More of that white **** coming down. I've got blisters on my hands and a kink in my back. I think that the snowplow driver waits around the corner until I'm done shoveling the driveway. *******.
Dec. 25 - White Christmas? More freakin' snow. If I ever get my hands on the sonofa***** who drives that snowplow, I swear I'll castrate him. And why don't they use more salt on these roads to melt this crap??
Dec. 28 - It hasn't stopped snowing since Christmas. I have been inside since then, except of course when that SOB "Snowplow Harry" comes by. Can't go anywhere, cars are buried up to the windows. Weather man says to expect another 10 inches. Do you have any idea how many shovelfuls 10 inches is??
Jan. 1 - Happy New Year? The way it's coming down it won't melt until the 4th of July! The snowplow got stuck down the road and the **** head actually had the balls to come and ask to borrow a shovel! I told him I'd broken 6 already this season.
Jan. 4 - Finally got out of the house. We went to the store to get some food and a goddamn deer ran out in front of my car and I hit the bastard. It did $3,000 in damage to the car. Those beasts ought to be killed. The hunters should have a longer season if you ask me.
Jan. 27 - Warmed up a little and rained today. The rain turned the snow into ice and the weight of it broke the main limb of the oak tree in the front yard and it went through the roof. I should have cut that old piece of **** into fireplace wood when I had the chance.
May 23 - Took my car to the local garage. Would you believe the whole underside of the car is rusted away from all of that damn salt they dump on the road? Car looks like a bashed up, heap of rusted cow ****.
May 10 - Sold the car, the house, and moved to Georgia. I can't imagine why anyone in their freakin' mind would ever want to live in the God forsaken State of Iowa

Seriously - it is a nice place to bring up a family. The local P-car club is small and active. The RSR typically got a lot of attention whenever I used to take it out, lots of questions like "what sort of V8 does that have in it?" It should be interesting when I get it out again this summer.:eek:

juicersr - really good questions. If I had to do it over again I would most likely go a different route. I always planned on running individual coil-pack / crank fire style ignition as I have it in my 930 and it works well. Additionally I will be running a Haltech ECU that can has 12 individual coil outputs so tune ability shouldn't be a problem.
With the extra components that I had to package into the engine compartment (turbo plumbing, larger inter-cooler, taller manifold, injector risers, fuel rails etc.) I was concerned about fitting the 6 twin post coils and routing the ignition wires neatly and reliably. I looked at Coil Near Plug setups, but still wasn't happy with the mounting of the coils. I then looked at some COP setups and thought that it provided a neat and tidy setup. I liked the idea that they eliminated all of the spark plug wires, from a inherent reliability point of view and would package well near the valve covers. I have some concerns from a performance perspective however as I planned to run some CDI units to fire the coils, I figured that they should have enough fire power.
From a cost perspective I consider that it is about even. The 997 COPs were purchased from our host ($42 x 12) and I had to also buy the primary wire connectors (Ballenger Motorsports for ~$10 each). I figure the primary wiring is about even. Mounting of the COP's is where I have a lot of time invested. I originally designed some mounting plates only to find that the actual spark plugs that I was planning on using were 5mm shorter. So I had to modify the mounting plates and relieve the valve covers. It would have been ideal if the spark plug boots on the COP's were 10mm longer, however as I already purchased them, I persevered. Ultimately I am planning to cast a set of custom valve covers that would incorporate some posts to mount the COP's but want to make sure they work before investing any more time.

Richard.

That's funny as hell. I was born and raised in IL and lived in Indy for 7 years so completely relate.

Great work on the machined parts, don't get too carried away or the entire car will be rebuilt!

Great stuff, you can always say, no my 'slow car' has the V8, haha. Not too often the daily-driver is a hot car too.

Glad you are enjoying Iowa, I still like it there and elsewhere in the Midwest I've lived while growing up (Kansas and Wyoming). Strange that I end up settling down where I least fit into the area (Washing DC area).

Re: Your Snow story....I'm from Buffalo, NY....eastern end of Lake Erie with prevailing westerly winds. Not unusual to get LES ( Lakes-Effect-Snow) dropping 36" of snow overnight. Winds pick up moisture over the lake and drop on the cold land mass. Lake is the size of Austria so doesn't "freeze" until maybe February. Winter goes from about mid November to mid-April.

... can relate.

Hrumpph......you baby !... :)