"Barn find" 1986 911 turbo

[PMORG98]

Just read through from page 1. This is a great story! Going to follow this all the way till you finish it. I can imagine how thrilling it must have been the first time you laid eyes on it. We vacation at Kure Beach every summer & I would love to see your project in person next summer if you live anywhere near I-40.

[reclino]

The two coats of paint seemed a bit rough to the touch, so I scuffed both housings down with scotchbright and layered on a heavy top coat. Hard to paint outside at 32 deg, but I only left them outside long enough to spray, then quickly brought inside to dry on the kitchen table. Wife just got out of the shower and asked if I was painting my nails?!!!! Not my nails.😀

[reclino]

Mechanical progress on the 930 has seemingly slowed as of late. Work, life and side projects all seem to demand time. One exciting side project has been working on the rebuild of my wastegate. This project is covered in detail in it's own thread.
http://forums.pelicanparts.com/911-930-turbo-super-charging-forum/972314-930-wastegate-rebuild-nla-parts.html
So I have gone from a used crusty part to a new lease on life with the reproduction of 3 different 930 parts.




Porsche didn't make the parts available, this however gave me a great opportunity! I am now the only guy in the world with these 3 930 wastegate parts for sale.
Valve guide
Intermediate gasket
Spring Shims

David
#930MOAB
Performance EngiNERDing
Engineer.white@gmail.com

[reclino]

My son Morgan has gotten AutoCAD Inventor through his school and has gotten pretty good at using it. I suggested if he were to model up a part I had in mind for the Porsche I would get it 3D printed.




I set him down with the MOMO steering wheel hub and spacer I had assembled. I really didn't like the look of the different pieces screwed together. I suggested he measure the hub and spacer. Then design a cover to slip over them. This will make it look like an old school solid adapter.




I went and picked up the prototype today!




It fits the assembled hub and spacer perfectly!



We left it a bit long at the bottom, we will trim this to be a close fit to the clamshell housing in the car, the Momo hub leaves a pretty ugly gap here.



The part was printed at high speed with PLA resin, I will let Morgan sand it down, measure and trim it to fit the car and paint it with wrinkle black paint. Then we will print a final version with ABS plastic!

[baloo]

Excellent! ! More!

[flightlead404]

Sweet. I bought a 3D printer over xmas and have been having a lot of fun making fascia for displays, brackets and gears for some Alexa-controlled blinds I'm building, and looking at playing with some lost wax type casting using PLA and baking it out. They are lots of fun and not just a toy anymore. I'm learning a lot about mechanical design. I'm sure some 3D printed parts will end up in the 930 soon, like a printed radio delete plate with some built in controls for Bluetooth amp and AFR display.

[78-911SC]

Maybe he can make a cover for the passenger fan.

[reclino]

I think we left off somewhere around here. Now I have a pink granite Starrett surface plate instead of a piece of granite countertop.

[reclino]

[reclino]

Staying at home has its benefits! Decided it would be prudent to rebuild the brakes. Let's start at the front. Seals and wipers can be removed with no damage if your really careful and take your time. I modified a couple of plastic scrapers to wedge the wipers out of the calipers.

[reclino]

Clean, paint with VHT black brake caliper paint, clear coat with same, and bake in the smoker. Then rebuild with new seals, wipers and proper brake caliper grease.

[reclino]

Quick look at what we are starting with.





Since the brakes are off, let's clean and repack the wheel bearings.

The original made in Germany bearings looked perfect, so just replaced the seals and grease.

[reclino]

Not sure why Porsche left this face of the strut bare steel to rust. I wire brushed it, primed with zinc chromate, and top coated it grey. Soon to be hidden.


Wire brushed hub on the right, bead blasted on the left.


Much cleaning, masking, bead blasting, painting and baking later.


New rotor's really look massive.

[reclino]

You poor dirty thing. Let's clean you up a bit.


Looks like your identical twin needs a bath too.


This could take a while,.

[reclino]

The boy is going to need some PPE for the next task.
Let's zinc plate some parts.

[reclino]

Cleaned and painted the brake shields, but there were rust bubbles that kept popping up.
Burned off the paint and started over.


After the paint was toast, bead blasted the rust, acid etch and zinc plate.






Little bit of paint and right back on the car.

[reclino]

That was cool, let's put something else on the car!




Brake pad wear sensors. The rear ones at Rock Auto we're dirt cheap, so a bit of careful trimming, soldering, and shrinkwrapping and rears can become fronts. Maybe someday I will become a real boy.

New pads

With the ability to zoom in and focus, a piece of perfection is clear.

[reclino]

Engine progress.
Cylinder heads are with Craig Garrett for rebuild.
They are getting the following
New TRW sodium cooled exhaust valves
New Eibach valve springs
Colsibro valve guides
Titanium valve spring retainer's
He may deck the head to cylinder surface, there was a bit of scuffing there.


At 68,000 miles the exhaust valves were showing their age.

[reclino]

I am a mechanical engineer, and a hack mechanic, but I am not an engine builder. I would like to split the case on this engine, and get an assist from someone on the rebuild. I am good at doing the detail work of cleaning and preparing parts. I have enough friends who are machinists that I could probably source all the precision measurement tools, but at this point in the build I feel it'a probably worth it to pay for some expert Porsche engine help. I have reached out to a couple engine builders on the east coast to at least get a better idea of the cost of their service. If anyone has a recommendation of a "local" expert engine guy drop me a line. I have family up in Maine so really the entire east coast is "local". Though it sure would be nice to find someone in North Carolina.

[kamaro]

If you reached this far, I don't think rebuilding an engine would be that hard for you. I say go ahead and do it yourself, you'll feel so proud when you get it done.