Winter engine rebuild project

b930 · 06-08-2015, 06:05 AM

Getting a bit cold in Australia so I thought I would go about the next stage of motor upgrades. I have a nice set of 3.2 heads twin plugged with Turbokraft performance valve and spring package fitted. Also got 964 cams, and a nice carrera manifold and full bay intercooler bought from a fellow pelicanite as shown below (not my engine).

Dropped the motor and started tearing it down last weekend

Other items per my sig, will use the existing GT30 twin scroll and twin gated rarlyl8 headers. I'll be running coil on plug for all 12 plugs off 4-three channel igniters.

One thing I need to decide on is P&C's. I'm thinking 102mm machine in cylinders with 8.0:1 CR Pistons for a 3.65L, but can't find any stock!!

For rods I an thinking stock with ARP fasteners and keeping red line 6500. Head studs also ARP. Will be interesting to see what this set up puts out......
I'll snap some more pics as I go.

boosted79 · 06-08-2015, 10:04 AM

What COP's are you using? I'm planning a similar build but staying with 3.4L, I'm considering COP but not sure it's worth the extra expense.

Tippy · 10:30 AM

You will be WAY out of breath with the GT30. You will have some serious flow. I'd get a GT35 or 40. Also, you'll need 1 5/8" headers for the Carrera heads.

b930 · 06:43 PM

Hi, I'm using denso dumb coil sticks from a 600cc bike. I also use these in a cosworth powered mk1 escort and they work great.

Also I have 1-5/8" headers already. I hear what you are saying on the turbo, but I have the GT3582R with 1.07A/R housing and not the GT30. I reckon it will get me a decent 600-650 hp. I plan on getting a Borg Warner EFR maybe next year.

Cheers.

Tippy · 06-08-2015, 07:16 PM

You're totally set then. I HAVE to hear your boost onset (RPM to hit 1 bar in 4th) numbers when complete.

That thing is gonna be sick! GL.

b930 · 06-08-2015, 07:51 PM

Cheers, yep it should be totally nuts. This is what the boost onset is like already with the current set up (std P&C and heads, SC Cams, twin scroll GT35).

0.5 bar at 2200 rpm
1 bar at 2900 rpm
1.2 bar at 3000 rpm

http://youtu.be/NhHYF3mlU4o

Tippy · 06-09-2015, 07:12 PM

Quote:

Originally Posted by b930

Cheers, yep it should be totally nuts. This is what the boost onset is like already with the current set up (std P&C and heads, SC Cams, twin scroll GT35).

0.5 bar at 2200 rpm
1 bar at 2900 rpm
1.2 bar at 3000 rpm

http://youtu.be/NhHYF3mlU4o

Nice! Please report back when done.

b930 · 06-14-2015, 02:56 AM

Motor all stripped to the block

Interesting to note the difference between the 930 heads and 3.2 heads on the port size.

Big valve twin plug 3.2 head on right.

Tippy · 06-14-2015, 06:24 AM

^ why every 930 owner should be running these heads!

Couldn't believe folks here were hung up on, "oh, the casting is better on the 930 heads". So what? Mine have been running over a decade over 1 bar without cracking or fatigue.

Nice photos!

IMR-Merlin · 06-14-2015, 06:30 AM

What are you using for engine management? I would love to go this route and get rid of my electromotive coil packs with associated plug wires. Looks like a much cleaner install!!

Quote:

Originally Posted by b930

Hi, I'm using denso dumb coil sticks from a 600cc bike. I also use these in a cosworth powered mk1 escort and they work great.

Also I have 1-5/8" headers already. I hear what you are saying on the turbo, but I have the GT3582R with 1.07A/R housing and not the GT30. I reckon it will get me a decent 600-650 hp. I plan on getting a Borg Warner EFR maybe next year.

Cheers.

boosted79 · 06-14-2015, 07:47 AM

"What are you using for engine management? I would love to go this route and get rid of my electromotive coil packs with associated plug wires. Looks like a much cleaner install!!"

x2
b930 - what specific 600cc bike are those sticks from? Merlin, Clewett has a TEC3r kit for the 996 that uses COP so it can be done, probably just a matter of getting the right harness and programming the TEC for one coil per plug? It sure cleans it up.

b930 · 06:37 PM

Hi,
I use a Performance Electronics PE3 ECU. It runs full sequential ignition, and has 6 logic level ignition outputs. It does have 4 ignition drivers in it so I can run wasted spark right out of the box (direct wire dumb coils) but I wanted full sequential, so use 6 logic level outputs and a pair of Bosch 3 channel igniters. The Bosch igniters run the denso coil sticks.
One thing I need to experiment with twin plus is running another pair of bosh 3channel igniters for the lower plugs. I think I can just wire the second pair of igniters inputs in parallel off the 6 logic level outputs of the ECU.

I have to run a pull up resister on the 6 logic level outputs as it is, so maybe at worst, I may have to adjust the value of the pull up. Anyone know if this will work?

PE3 is a great unit by the way, very cost effective, made in the USA and very easy to tune. Both my 930 and my old 73 Cosworth powered Escort start and run like modern cars with no hiccups at all.

The short Denso coil sticks are from 600cc bike, fireblade I think. There are a bunch of bikes using the short sticks which suit the 930 better such as a Triumph Daytona 600. Long sticks from 1000cc bikes work as well (I have used them before) but stick out a bit too much for my liking.
Cheers.

krasuskyp · 06-14-2015, 06:47 PM

Quote:

Originally Posted by b930

...and my old 73 Cosworth powered Escort ...

*ballar*

pics, yes!?

great pics, love the big ports / valves

sounds like it's going to be a killer build, I'd love to run something like that. No, wait - stock is moar betterer

b930 · 09:06 PM

Ballar indeed, pics :-)

YB motor, T5 box, BW78 axle w/ LSD, big brakes, etc (too much to to go off track on this thread!).

940kg fuelled, screwing the nuts out of the T3 at around 26psi midrange, with a big intercooler, big injectors, PE3 ECU sees around 350 hp, and around 380lb.ft. With only only 940kgs to move it flies! Tempted to run a bigger turbo but just love the punchy T3.

I think its the only street legal (fully engineering) cosworth powered mk1 in Western Australia and one of very few in Australia.

b930 · 06-14-2015, 09:11 PM

IMR-Merlin · 06-15-2015, 05:24 AM

Quote:

Originally Posted by boosted79

"What are you using for engine management? I would love to go this route and get rid of my electromotive coil packs with associated plug wires. Looks like a much cleaner install!!"

x2
b930 - what specific 600cc bike are those sticks from? Merlin, Clewett has a TEC3r kit for the 996 that uses COP so it can be done, probably just a matter of getting the right harness and programming the TEC for one coil per plug? It sure cleans it up.

looks like I'll be building a new harness this winter.

boosted79 · 06-15-2015, 06:23 AM

That is one nice car, you do great work. I don't understand why Ford didn't bring them into the states. I looked at the PE3 site, very interesting. Not crazy about the crank wheel though, only 12-1 pattern vs 60-2 for the Electromotive. But you can't argue with success. Looking forward to your build. Those sticks are on ebay for $30 used for four, way way cheaper than having to use two 3-coil DFU's, wires and caps. Can you tell me the Denso part number on the stick? I'd like to see what they are new. Thanks.

IMR-Merlin · 06-15-2015, 06:31 AM

Quote:

Originally Posted by boosted79

That is one nice car, you do great work. I don't understand why Ford didn't bring them into the states. I looked at the PE3 site, very interesting. Not crazy about the crank wheel though, only 12-1 pattern vs 60-2 for the Electromotive. But you can't argue with success. Looking forward to your build. Those sticks are on ebay for $30 used for four, way way cheaper than having to use two 3-coil DFU's, wires and caps. Can you tell me the Denso part number on the stick? I'd like to see what they are new. Thanks.

I have a motorcycle salvage yard I am sponsored by. So I can probably get 12 cheap. I'd love to know how to convert the wiring on my Tec3 6/12 to run these.

IMR-Merlin · 06-15-2015, 06:31 AM

And that is one badass Escort!

boosted79 · 06-15-2015, 07:13 AM

"looks like I'll be building a new harness this winter."

Do you have TecGT or Tec3R? I don't think the GT will drive a twin plug six cyl. with one coil per plug since it only has four inductive coils built into it. It needs the DFU's that pair two plug leads to one DFU and uses wasted spark. The 3R has six coils built in. Clewett says use the 3R for twin plug six cyl with one coil per cylinder.