The engine is finally rebuilt. It took a little longer than expected, but went really well.
Now I can shift to the final development of the turbo system. I started mocking things up on the engine and found a couple issues.
First when you twin plug the heads, the lower plug on the 1-3 side of the engine is very close to the exhaust flange. I can still mount the coil, but it is way too close to the exhaust. I don’t think I can keep it cool enough even if I add insulation. My plan is to create a 12 inch extension wire and mount the coil on top of the engine. I have not really seen people do this before with coil on plug coil. I don’t see why it wouldn’t work though.
Also, when I added the thicker cylinder base gaskets (1.2mm) this made the exhaust flanges misalign. The crossover pipe flange is now about 2 mm back from the heat exchanger flange. I think I’ll just double up the gaskets and that should work fine.
Now I’m focused on building the CAD, prototypes, and test fitting. It’s a little tempting to put the turbo where Porsche put it, but I still like the side mount and I like that it puts the weight further forward. I’m sticking with it!
