Installing 95 993 3.6 into 69 T/RSR

[BoxsterGT]

I see your Oil Hardlines are not connected to the thermostat yet.



Did you have any fitment issues at the front fender closing panel? I had a tough time getting them to fit properly. On my 70 the closing panel is curved and the hardlines sit an inch or so further forward making a fitment problem with the thermostat at the rear.

Len

[rennch]

Hey Len,

That was a quick mock up...first time I'd put the lines on at all. Just fitting the clamps and such. Today I'll work on the thermostat, and hopefully get some soft lines on as well. I haven't run into any major fitment issues yet though.

Question...what's a front fender closing panel?

[BoxsterGT]

Its this vertical panel in front of the A pillar & door hinges..........



The early cars had the Oil Hardlines run up between the door and this panel, then through the actual panel like this.....




Len

[ted]

Yours may be the last 3.6 swap build this forums sees for long while.
Its deja vu as Jae Lee at Mirage International did most of my swap too.
will it see mostly street drives? any track time?

[rennch]

Ted, what makes you say that?

Today we got the Patrick Motorsports flywheel on, and notched the transmission for the crank sensor.

Here's the motor off the stand,with headers installed:



And with the flywheel:



Notched transmission:



With some brethren.



It's getting to be crunch time, so I'm doing my best to not freak out that I'm leaving for rennsport in 1 week from tomorrow!

Question for those of you interested in this swap: If you were prepping to do the swap (mostly yourself) and there was a "how-to" video that took you through the process, including diagrams, parts list, tool list, etc, how much would you pay for it?

$47?
$67?
$97?
Something less, you cheapskate?




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[quattrorunner]

Pay more. It would be worth it to someone wanting the car driving.

[POORSH]

count me in if you are putting a video together.

[rennch]

Much more than that. I'll unofficially announce here. Jump on our mailing list for the launch date here: http://rennch.com


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[ted]

Originally Posted by emptyo

Ted, what makes you say that?

I hope we see more swaps.
I think the prime time for 3.6 swaps was 10 years ago.
When low mileage 3.6 motors were common and aircooled 911 prices were reasonable.

Today a high mileage 3.6 donor motor could use a refresh.
Another consideration is that Stock air cooled 911s have doubled in value in the last 5 years.
So the cost to do the swap with engine rebuild and increase cost of the platform,
and perhaps loss of stock 911 value makes the swap less desirable economically.

Rebuilding my 911 with a 3.6 swap was a fun project that has given me a decade of driving and racing excitement.
Jae was a big big help too!!! No regrets!
I only wish the 911 culture still supported engine swaps and 911 track car builds.

Here's Jae and I warming tires at Chuckwalla.
Drive that bad boy over to La Mesa for a cold one when you get'r done.
https://youtu.be/aB9ubMvxLl8

Just had my 3.6 refreshed last year for the 2nd tme, the original pistons and cylinders still looked great.

[911 tweaks]

awesome vid ted... a few q's please...
1. is your car the black 911 w/ the hi rear wing...? the car looks like bb2 = jack olsens car possibly...?
2. was jae hitting the rev limiter a turn or 2 after the white wall straight away = if so what rpm...?
3. is jea car a stk 3.6L or modified..?
4. what trans is jae car using...?
5. the car jae was trading the lead with... what is that cars set up...?
thx for sharing & i agree the long hoods getting body mods a/o big motors requiring a lot of change to the 911 tub vs leaving it stk may be times behind us...

[mikeferg75]

Nice Michael!

See you at Rennsport!

[Antonov]

Awesome. Tell Jae Dino says Hi.

[ted]

in fact many early S race cars are being returned to stock.

Originally Posted by 911 tweaks

awesome vid ted... a few q's please...
thx for sharing & i agree the long hoods getting body mods a/o big motors requiring a lot of change to the 911 tub vs leaving it stk may be times behind us...

Not to hijack...
yes video was from this car.
ted's Garage :: Shape shifter, Excellence magazine 11/2010.

Call Jae he set up both cars, mine on bias ply slicks and his on radial slicks.
I think I have 800 rear and 600 or 400 front track springs now.
Jae had a 3.8 with a G50 close ratio 6 speed that day I think?
Mirage International.
Mirage Intl - Porsche parts and tuning

[rennch]

Clutch installed today, as were the rear oil lines and thermostat. This thing could make noise tomorrow if all goes well!



Cool lighting, and funky shot:



I also finished my Kevlar block off project. It was my first time riveting anything. I could have gone black rivets, but I thought the silver had a racy look.




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[rennch]

Electronics sorted and bolted down in the cabin:



And they are married once again:




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[911 tweaks]

awesome michael... anyway u can upload smaller pics = ones that fit the pelican/computer screen or is it me...? carry on...project is going great...

[rennch]

So, this sucker is giving some very trained professionals (and one hack...me) some real fits.

Today was a massive struggle, because the main (21 pin) harness plug had been cut off on the DME side, so we had to fabricate two entirely new plugs and sync them up. But...all the wires didn't necessarily sync. So, it was a real challenge, between that and the fact that its a 69, and doesn't have the standard 14 pin connector. I got there at 3 in the afternoon, and they'd been struggling for hours with the engine in the car, but not getting any fuel from the fuel injectors. It turns out that in the new wiring harness, there was a single wire that wasn't quite connecting.

Once they figured that out, here was the first result:

https://www.youtube.com/watch?v=3ZVMw5PKqh4



So...it made some noise...but barely. And boy was it ugly.

After plugging a few vaccuum holes, and installing the muffler (which, in and of itself, was a huge hassle. It didn't clear the engine console we were using, so we had to beat the living hel....errrr....modify the muffler a bit, until it cleared.

Anyway, here's that end result, post muffler:

https://www.youtube.com/watch?v=YNpsYf4zhTM



So...started, but sure is ugly.

Sounded like we had a bad cylinder. So, they decided to do a leakdown:

1: 19%
6: 19%
2: 11%
4: 12%
3: 19%
5: 12%

Good leakdown numbers, especially with a motor that's been sitting for a long time that I have literally NO history on. Those numbers should get better as it runs.

As they did the leakdown, they pulled the plugs. They were awful.

So, Monday AM we'll do new plugs (how did I not change them when it was out??) and new distributor caps. It looks like the motor had been steam cleaned or pressure washed, then just SAT. Which is bad, apparently.

So much for getting a chance to drive it for a few days to "shake it out" before I drive it all the way to Monterey for Rennsport on Tuesday!

I still have a TON of other stuff to do...bumper mods, seals, interior stuff. No way I'll have time at this point. But I'll do my best to get it together.

[rennch]

Some pics of the oil system:












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[quattrorunner]

That's a cool car. It's a bummer that it's not going to be ready to go to Monterey.
I had a similar situation this week. I finally got everything lined up and ready to put my engine in after a very busy few months at work and home as well as changing everything to fit a 930 tranny into a 911 car. There are lots of changes to be made. Anyway I did them and last week I got it in and it fit. It drive awesome and was a blast but as soon as I tuned the engine and was getting good afrs in most of the ranges for a turbo car it was clacking from the clutch. Turns out my aluminum flywheel came loose and was moving. So out came the engine again last night. I'm now waiting for a new flywheel. Then back in again. At least I know it fits.
It takes some time to get everything correct in a project like yours and there is no way to prepare for everything. There is always something that will trip you up. I was hoping it would be smooth for you but in the back of my mind I knew it wouldn't be. There is always something. Don't sweat it because once it's running smoothly all the frustration just melts away and joy takes its place.
It's things like loosing $150 worth of mobile one liquid gold that burns my butt. Well also loosing $600 in flywheel debacles.
Your car is really cool. It will be awesome once it's done.

[rennch]

Originally Posted by quattrorunner

That's a cool car. It's a bummer that it's not going to be ready to go to Monterey.

Bite your tongue sir. It will BE in Monterey, if I have anything to do with it.