Evolution of a Carrera RST

[Uwon]

Off to the body shop-Bromleys Automotive in Orillia who have done some nice stuff for me in the past.


The exterior of all body panels were all stripped.....



There were a few surprises lurking under the paint. Note the long indentation lengthwise on door.


And then built up to the primer stage.....



Hey Rich, recognize the holes on the frame inside the left rear fender?

[quattrorunner]

Me like.

[Uwon]

To continue, the primer and prep was followed by a coat of Signal Orange Glasurit paint on all interior, trunk and engine bay surfaces. I am not building a lightweight so the underbody was left alone as the galvanized body and undercoating remains solid save for some minor scratches which occurred during transport.


My original intention was to instal all the electrical and mechanical at this stage but I have not got there yet as orther things in my life and the engine rebuild have taken precedence from time to time. I have left the body at this stage for almost one year which has given it a chance to show up any final blemishes that seem to crop up as the prep and primer shrinks (some may dispute this but it works for me).
Next, engine rebuild.....

[Uwon]

I dropped the motor out of the wreck. It is not such a cumbersome chore as there is less plumbing and things hanging about with an Electromotive Engine Management system and no pollution controls.
I was really concerned that the motor had been damaged as the car really hit the wall pretty hard. First evidence of damage was the left bolt that mounts the rear engine saddle bracket to the left case.

The tin around the motor was also pretty well chewed. Not good. I had visions of an unusable case and bent crank so I decided that a complete teardown was necessary.


Flame rings looked OK and re-usable.




And the short skirt RUF, i believe) pistons looked worse for wear.

Splitting the case did not indicate and other issues.



More tomorrow.
Cheers.....

[Rich76_911s]

Originally Posted by Uwon

Hey Rich, recognize the holes on the frame inside the left rear fender?

I sure remember that one with the WELD sign on it. Pulled off that spring plate and saw the weld split in there. The other two aren't as sharp in my mind, too much grinding of undercoating since then.

[Uwon]

I completely disassembled the motor and fortunately did not find any other visual damage aside from some gravel rash on the bottom the case and the exhaust heat exchangers which were completely trashed.
I forgot to explain that this motor is a 3.2 converted to a 3.4 twin plug turbo using the electromoive tec3r engine management system. Lots of power and equally happy on street and track.
After some discussion with local folk on the state of the 3.4 pistons and ciliders, I decided to send them to Charles Navarro at LN Engineering for further assessment. Charles advised that he had seen and refurbushed pistons and cylinders that were far worse than mine so I decided to have LN do the necessary work. LN stripped, replated and honed the cylinders to 98.00mm. pistons were stripped, top ring lands and skirts were coated. Charles also matched new rings- AP stainless top rings and JE for the balance. Unfortunately I cannot find pics of the beatifull completed work that LN did.
In the meantime, I sent out the cams for refurbishment to SC specs, assembled all the new seals, bearings, gaskets, nuts, etc. that I needed for the rebuild. I did also buy a new intermediate shaft/sprocket assembly and disassembled and inspected the 964 oil pump which looked brand new even after over 300,000 km.
I pondered for some time whether I should takle the long block myself. I was really concerned about screwing up the crank assembly so in the end I decided to have Jay Lloyds of Loyds Autosport do the long block as he did the original conversion some ten years earlier. He rebuilt the broken knob on the left case, did the final clean, inspection and reassembly of the long block. He also repolished the rod beams, drilled larger oil feed holes, fit new pin bearings and honed them to the orrect size. All internal parts were rebalanced. Forgot, crank was sent out and checked for cracks, spec which ere all good. Here are some pics of Jay's great work:

[Uwon]

Jay Lloyds also did the heads for me with new guides and intake valves (exhaust were still really good), new seat facing, re-ported and polished, etc. Note the twin plugs for the Electromotive tec3r. Here are some pics:













More pics next week.

[RWebb]

"I sent out the cams for refurbishment to SC specs"

- this doesn't seem to comport with the extensive hotrodding of the motor (?)

[Uwon]

RWebb. I agree that the SC cam does not sound very aggressive. There are lots of new "hot" cam grinds out there but I' m going to stick with what works for me. It doesn't spit, fart, backfire or buck-just runs well under all circumstances.
By way of background, All editions of the late Bruce Anderson's Performance Handbook discuss the SC cam as an alternative for performance improvement for a turbo motor. Back in 1999, I had the opportunity to correspond with Bruce prior to my initial turbo conversion and he convinced me to go with the SC cam grind to suit my objectives- daily drivability and DE track performance. He was right. I have driven the car since the conversion over 300,000 km over 10 years and have tracked it about 10 days per year over the same period. With only .6 bar boost, I can consistently hit 265 kph on the (up hill) back straight at Mosport (that's red line with a stock 915 trani). Can't get more exhilarating then that.

[Uwon]

Got the long block back from Jay Lloyds in the trunk of the old Audi.



A little bit of help from inside the trunk to get the motor to the right hight for the yoke.


And there she is.

Motor is now assembled and off the engine stand. I painted all tin, intake rails, etc. As the heat exchangers had been badly dented in the crash, I purchased some used ones from a fellow Pelican. By the way, I went through two sets of SSI's over a few years which developed pin holes which were periodically welded up by first removing the heat exchanger box. I finally gave up on them and went to the bulletproof standard 930. Nothing is worse than fumes in the car in the cold, never mind the danger.

[Matt Monson]

Neat project. Looking forward to the rest of the story.

[Uwon]

Thanks Matt for your interest.
I forgot to mention in my last post that the 3.2 intake manifold has been polished up and the throttle body area opened up and smoothed out.
I am also using a Kennedy clutch which I had originally installed only two weeks before the crash. I can tell you that it felt really good on the track with no slippage at all up the back straight.
I re-installed the trani without doing an R&R. I cannot remember if it had ever been opened up but since I am not hard on tranis I decided that I would just clean up the exterior and replace the nuts and bolts.
You can also see in the pic above that I had my massive intercooler placed and temporarily held by some soft aluminum brackets. I am hoping to stuff this huge thing into the engine compartment and still be able to close the ducktail lid. At this point I remeber that I was leery that it would work.









And there we go-the lid closes.

[Uwon]

I have two different turbos in my parts bin. A K27 7006 on the left and a 3LDZ "spare" on the right which was originally on the car probably pre-2002.
Many thanks to some fellow Pelicans who helped me ID these two turbos.

Help ID these Turbo Units

I know that the K27 never ran out of boost on the track. I remember that the 3LDZ on the right had excellent low end response and was great for street use but I cannot honestly remember whether it ran out of oomph up the back straight. I decided to use the K27 for now.



I recently got from RarlyL8 a Street Hooligan center exhaust muffler. What a work of art!! Simply beautiful !!





.


Still waiting for a little extra addition from Brian at RarlyL8 which hopefully will arrive next week

[Shaun @ Tru6]

Jewelry!

[Guardsred911]

Love the ghetto fab engine jack where you manage to use not 1, but 4 milk crates, 2x6's, a dolly and a jack..... Nicely done!!!!!!

[Uwon]

The dolly is the bottom portion of the engine stand. The jack is a Costco special which has a 10X12 jack head. I took the wheels of the jack so it would not move around. Now the milk crates are a left over from my son's university days-if only these crates could talk..........

[911SauCy]

So I currently rock a Targa...but this is my (what I feel is realistically attainable) dreamcar.

Turbo 3.2 or larger, G50, coupe, narrow fenders, and a ducktail.

What an AWESOME combo...not to mention sleeper!

Simply fantastic.

[porterdog]

Originally Posted by Uwon

...Signal Orange....

Oh hell yes.

That looks like real fun right there.

[Uwon]

Thanks guys for your interest. I'm pretty excited to finish it but as we all know everything seems to take 5 times longer than you first thought.

[vintagecarlover]

nice, nice nice. I want to see detailed finish. love the color.