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 Post subject: Re: 944 S2 Repair
PostPosted: Thu Aug 03, 2017 11:12 pm 
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Couple more pictures of pistons installed . Rings are Total Seal and I used one of those hand wheel ring file machine and got to say what a brilliant time saving gadget . The rings usually take me a day to do with a hand file but got these all done in about three hours. And another new gadget was the solid tapered ring compressor again so easy to use with pistons pushed in just using my thumbs rather than the ratchet style where the pistons sometimes have to be forced in .
As expected the pistons sit down in the bore 0.125 even with having had the deck shaved to 9" from 9.060. Not ideal for squish but I know of a few people running the same or more with thick gaskets without any undue effect on performance . With a dish of -30.9 , Cr works out at 8.47:1 . If you look at the last pic you can see there is about 4mm of clearance between the bottom of piston and the large crank counter weight and a small part of the piston is just below the bottom of cylinder so I would suggest that this is the max amount of offset on these cranks. The reason I am using these is that they are of the shelf Ford sbc v8 pistons with a large symmetrical dish that should allow valve clearance without the need for valve reliefs to be cut (have yet to clay them) and I bought them new for £220 for 8 giving me four left over for another engine.


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 Post subject: Re: 944 S2 Repair
PostPosted: Fri Aug 04, 2017 2:24 am 
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I've just got a price for a set of 4 104.5mm Mahle turbo pistons for use in Alusil... £760 . At least I'd save on the liners/fitting.


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 Post subject: Re: 944 S2 Repair
PostPosted: Fri Aug 04, 2017 4:17 pm 
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Hi Pauly, good price on the pistons but you still have to have the engine bored ,honed and polished for the larger pistons at 104.5 and I found there is little difference in price between that and steel liners allowing a lot of piston options . If you do go down the first route , I have the sunnen stones , pads and paste you can borrow if you want to have a go yourself. Also just be aware that I believe some people have had an issue with the new coating on the Mahle pistons, but this is only what I have read .
I also chose to go the way I have to reuse the 968 crank that had the journal bearing damage .


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 Post subject: Re: 944 S2 Repair
PostPosted: Fri Aug 04, 2017 7:24 pm 
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Hello Simon, thanks for the offer on the Sunnen gear. The bores on my 2.7 block look unmarked, so they may be good to go with just a polish using the pads & paste. I'll have to get the bores measured properly. I think only Wossner do Alusil 104mm turbo pistons now though ?


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 Post subject: Re: 944 S2 Repair
PostPosted: Sat Sep 02, 2017 7:58 pm 
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Small update , managed to steal the play dough from the grand kids and check the valve piston clearances which were all good which was a huge relief as you can never be sure just by measuring , well I can't anyway .
Continued building up engine but have a small issue with the crossover as even though it was built on a dummy block and head I had spare it was 10mm to short which is really strange as it did fit perfectly , so will have to get it adjusted . As can be seen by the balance shaft cover that have been welded , I will not be running any balance shafts . Not a lot standard inside this engine to balance .
Fitted turbo , Holset HX35 , which is a snug fit but looks impressive ! Hope to have it all finished this week and fitted asap .


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 Post subject: Re: 944 S2 Repair
PostPosted: Sun Sep 03, 2017 10:56 am 
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Wont the crossover pull up to the turbo with a bit of heat from a blow torch?


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 Post subject: Re: 944 S2 Repair
PostPosted: Sat Sep 09, 2017 1:14 pm 
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It would do Pauly but don't want to put undue stress on other welds , easy fix with engine out of car . Soon as its adjusted the engine now ready to go back in car.
Couple of pics showing it needs two aston martin plenums to make one that's good enough for a Porsche !


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 Post subject: Re: 944 S2 Repair
PostPosted: Sat Sep 09, 2017 3:20 pm 
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Looking good. Those Mahle pistons I mentioned are 2618 alloy. I'm concerned about cold piston slap, that and questions about the coating and wear rate is making me have 2nd thoughts about them.


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 Post subject: Re: 944 S2 Repair
PostPosted: Sun Nov 12, 2017 9:50 pm 
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This lot turned up Friday from Peep in Estonia . COP should look good if nothing else !


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 Post subject: Re: 944 S2 Repair
PostPosted: Thu Nov 16, 2017 9:29 pm 
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Autotune or dyno?


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 Post subject: Re: 944 S2 Repair
PostPosted: Tue Dec 19, 2017 6:51 pm 
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Got a couple of hours on the car today and started to connect up the Vems ecu .
Todays top tip is to make sure you have connected all fuel fittings before turning on ignition , safe to say I have good fuel pressure .
Another good day over the Christmas holidays and hope to gat it started.


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 Post subject: Re: 944 S2 Repair
PostPosted: Thu Dec 28, 2017 4:06 pm 
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Its been a bit quiet on this forum over Christmas so I thought I would post some pictures of a mock up of next years waste of time and money . I will be using all the left over bits from my other engines to carry on with the dry sump engine I started .
I have had a couple of aluminium plates water cut for the oil console block off and for the alternator/dry sump pump . The company in Gosport now has these stored on cad so relatively cheap to get them recut for any one else.
The turbo is another Holset HY35W which is physically a lot smaller than the HX35 on the 16v but has a nice small 10cm exhaust housing as standered but will not clear the balance shaft housing. I cut and rewelded the mount by about 10 degree so now fits lovely .
The head is a spark plug fire damaged 2.7 I had repaired but unfortunately was not informed it was bent before they skimmed it (you can straighten aluminium heads) so nice and level one side and a banana for the cam side . Fortunatly Jay at Modus has skimmed the banana flat and measured and trimmed each vale stem to fit . Not ideal but should work .
That's the plan anyway. Simon


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 Post subject: Re: 944 S2 Repair
PostPosted: Tue Jan 02, 2018 3:14 pm 
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how much power /torque do you expect to get from the 16v engine?


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 Post subject: Re: 944 S2 Repair
PostPosted: Sat Jan 27, 2018 7:07 pm 
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Air filter looks a bit small.


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 Post subject: Re: 944 S2 Repair
PostPosted: Fri Mar 09, 2018 8:01 pm 
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It has taken a while to make a few adjustments with the exhaust . Not being able to weld delays things with having to mark pipes up getting them tack welded , brought back then altered again etc but all finished . I have put a 3" downpipe with a 4" flexi from the turbo to the bottom of the car with a v band as the original place for the join is a pain in the arse , and a new wastegate pipe. Also put in another afr sensor bung as one goes to the vems round gauge and the other to vems ecu , cant have one sensor do both. Got to thank my friend Steve for his welding skills and patience .
Managed to squeeze in a stainless heat shield for the turbo exhaust housing , don't know how effective this will be but got to help deflect heat from the intake .
First start the weekend !!


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