Porsche Enthusiasts Club Forum

Previous engine went pop, donor engine was sourced and installed by Curves Bodywork in Essex.

In the process the engine bay was completely stripped, all metal work was sent for vapour blasting, then either Zinc or Cadmium Plated and the engine cover was powder coated white. And i mean all metal work, down to the nus and bolts.

Loads of new parts put in at the same time, water pump, belts, cam chain etc... This was all done by the previous owner just before I bought it, when I went to look at it I couldn't resist, under the hood looks better than any 944's I'd seen, or any other cars for that matter.

I'll dig out the list of what was done and post it up.

I can only give Curves Bodywork the big thumbs up, apart from a little squeal on start up she's running like a dream.

It wasn't the cheapest 944 on the market but I think it was worth it.

looks really smart......yes post the list...........engine bay another job for the to do list

My 944 s2, which i am modifying for the track

Looks good, but very distinctive. Good job you use it on the track, the traffic cops would love you running around the streets.

kongsodoken you asked for it......here goes........

List of work done on H763 JNF September 2010 - Curves Bodywork Specialists Ltd, Essex

-Prepare vehicle for removal of engine underneath vehicle
-Set aside steering rack, carrier cross member, front roll bar and wish bones for restoration by customer.

-Remove remainder of main engine block from vehicle. Discard.
-Prepare engine bay for refit of replacement engine.

Works to donor engine supplied by customer, prior to fitting:

- Remove water pump, camshaft belt, balance belt, rollers and tensioners from front of engine. Discard.

- Disassemble camshaft sprocket and mountings/bearings and remove camshafts for inspection.
- Remove camshaft hydraulic tensioner
- Fit new tensioner with wear pads, banjo bolts and crush washers
- Refit camshafts with new seals. Fit new camshaft chain.
- Refit cam retaining bearings with loctite flange seal. Fit powder coated* camshaft sprocket housing and cam sprocket. Torque all bolts to factory manual instructions.
- Fit new gaskets to camshaft cover and cover bolts.

- Refit water take offs to cylinder head with new gaskets and hardware.
- Refit exhaust manifolds with sealing rings, gaskets and hardware.

- Fit new water pump with new gasket, hardware and thermostat.
- Fit new tensioners and rollers to front of engine (all 5)
- Install new balance shaft belt.
- Install new camashaft belt.
- Check alignment and timing as per factory manual.
- Torque all fixings as per factory manual

- Check condition of clutch. Found to be worn but serviceable. Re-fitted under customer instruction. Grease an re-fit clutch release fork and vapour blasted* bell housing.

- Refit vapour blasted* balance shaft covers with loctite and re-plated hardware - Torque all bolts

- Refit reconditioned* power steering pump with new belt and hardware
- Refit reconditioned* alternator with ew belt, ducting, hardware and cowl seal.
- Refit recondition* oil lines with new o-rings

Fit Donor Engine into vehicle:
- Refit all reconditioned* ancillary items to engine - intake manifold, fuel rails, radiator etc, etc.
- Fit seals and gaskets as required

- Fit service items supplied. PLugs, fuel filter, air filter, oil filter, sump washer and plug

- Refit steering rack, carrier cross member, front roll bar and wish bones

- Refill oil, power steering fluid, anitfreeze with new

- Complete final checks prior to engine start.

Commission engine:
- Carry out post re-commission checks and top up fluid levels as required.
- Ensure all systems functioning as correct

- Reinstall headlight linkage
- Carry out pre MOT inspection

*All reconditioning carried out by third parties and supplied in such state.
All new parts and service items / fluid supplied by customer
Donor engine supplied by customer

Further list of work carried out or parts used:
Bonnet catch & lock: Removed, replated and regreased
Boot catch & lock: replated, lock fully cleaned and regreased
Rear light lenses: Removed, cleaned and refitted ith new 'black' sealant
Clutch bell housing: Removed and vapour blasted refitted with replated hardware. Release fork cleaned inspected and needle bearings regreased.
Front of engine seal kit: New fitted (along with belts etc)
Front and rear timing belt cover: Fully removed and cleaned replated hardware fitted
Belts: All new fitted
Roller / Tensioners: New fitted (all 5)
Water pump: New fitted - fitted new hardware (not replated)
Thermostat, seating, shim and snap ring: New items fitted
Engine wiring loom: Fully cleaned and inspected
Oil lines: Fully cleaned and replated. New 'O' rings fitted
MAF: Vapour blasted and reassembled with replated hardware. Mounting bracket repainted and refitted with replated hardware
Radiator reservoir and washer jet reservoir: removed and cleaned. Refitted with replated hardware
Main engine carrier: removed and fully cleaned
Front anti roll bar: Removed and repainted. Bushes checked and refitted with replated hardware.
Steering rack: cleaned and repainted, hardware replaced.
Power steering pressure line: New fitted recently
Front wishbones: fully cleaned and refitted:
Front fogs and indicators: removed, cleaned, threads waxed and refitted. Bumper voids cleared whilst out.
Interior fully cleaned (seats out)
General engine bay cleaned.
Boot area cleaned
Tool kit complete, spare complete with fixings. Jack present and working. Compressor present.

All mention of replating involved fully degreasing and dipping to remove all oxidisation.
Metal work is the re-zinc plated and yellow passivated
All plating professionally carried out by Halstead Plating Services Ltd, Essex
All vapour blasting professionally carried out by C&C Blasting, Essex
Powder coating by Eurocoatings, Essex
All other cleaning and painting by previous owner or Curves Bodywork.


.........and breath out!

Is that all !!!

WoW....I guess I need to save up a bit more to get mine looking like that ........

Who do you use for plating? cant find anyone local to me. Expensive?

Rich

try Midlands electroplating the are in Droitwitch so not a million miles away from you

I work as an engineer in aerospace and we get quote a lot of stuff plated, although a lot of our stuff is aluminim so we use anodising.

These guys are good http://www.ascotmetalfinishers.com/ and will do cadmium plating but might be a little high spec for automotive DIY.

Lots of places in the Birmingham area, I'll try and dig out some supplier names from work of some of the smaller shops

Expensive? Can be, but the process is done in large baths so sending lots of parts of a similar material type is often your best bet to get good value.

Well worth doing to keep things pukka long term.

Hi All

My S2. Only arrived this weekend. I'm totally smitten







All the best,
David

My P & J here:

Plus one of my old 924 (now sold, but I still see her around the place...):

6 weeks in and lovin it.