944 S2 Repair

[pauly]

Do those pistons have the same dimensions as the wossners, and is the battery located in the engine bay?

[sgl1966]

Hi Paul , no theses are slightly bigger as were meant for a ford v8 so 4.125” diameter .
Battery in boot , the cable is there to remind me to put it in before engine goes back in !

[pauly]

Ahh right. I sometimes take pics when I do work now. Doesn't stop me forgetting where I've put stuff down though .

[sgl1966]

Got all the bits and pieces together , spigot bearing , crank seal and clutch plate , so going to put engine in on monday all being well .
In the meantime I have had a brace made up that will take the mounts for the intercooler as well as having the new intercooler modified to reverse the flow which will free up a lot more room in the engine bay .
Also my ali rad from china turned up which doesn't look to bad . Went with this after reading other peoples experiences which seemed positive . This is one of the reasons for swapping the engine over in the first place as the old rad had developed a severe leak from the attachment of the end tanks . Mocking this up allowed me to judge where to place the remote electric water pump .
So to start necking the ibuprofen in preparation for the concrete floor on monday , mind you that's how most my days start getting older .

[scam75]

Beautiful work!

[sgl1966]

Thanks Stuart .
Managed to get the engine in today with its Kep stage 1 pressure plate attached . Got another day refitting bits and bobs and working out pipework . Unfortunately I will have to wait for my exhaust from AAS to be made and delivered before I can go much further .

[sgl1966]

This bank holiday conundrum , where to fit this !
Due to the electric water pump etc , I am doing away with the power steering pump and fitting one of these . Its the same pump porsche fitted to 997gt3 cup cars as well as zaffira and astra so £40 from the breakers . Looking at making a shelf where the cooling pipes for old pump were but that could change .
If anyone else fitted one of these , suggestions welcome.

[Wh1t3Kn1ght]

Awesome build - get that header tank replaced though it looks well grotty

[sgl1966]

Agreed , it does . On the list . Can get away with a cheaper s2 one as turbo oil cooled only .
So made up a small tray from some 6mm aluminium for the pump to sit on . Very tight fit but everything clears and it will get a decent airflow to help cooling . Running power from back of alternator through a 80 amp breaker from which I will also take a feed to the water pump next to it . Just need to get down to Pirtek next week to get the high pressure line made up . I believe the thread is m16 x 1.5 .
There is just enough room to squeeze your hand in to undo cap and use a funnel to fill . The other option is to use a small reservoir tank and pipe ala cup cars .
Best bit is it sounds like a small turbine powering up and you find yourself slowly edging away to a safe distant until it reaches pressure !

[pauly]

Didn't think I'd see it in the UK, but I'd say you've surpassed TurboTims 16v monster now. What's next, modern rear suspension setup?

[sgl1966]

Tim knew what he was doing , I'm not so sure !
Not for me Paul , but I do know of a gentleman who purchased a 2.7 head from me who is in the middle of fitting 996 suspension to his 968 . Should be an interesting build thread .
And of at least two other 16v turbo builds that will hopefully come to light.

[pauly]

The days when you could pick up a tired 968 for £4-5k are long gone. I looked for one to fit a turbo to over 10 years ago, but that Strange breaker seemed to be mopping them all up. I still reckon 400/400 is the sweet spot for 2wd, and without sinking too much time and money in .

[Waylander]

mine must have been not quite so tired at 6k, but its now 164k miles so very tired

[pauly]

mine must have been not quite so tired at 6k, but its now 164k miles so very tired

I contemplated building a 968 turbo for a long time, and TBH I didn't see many 968's for £5k or less. I guess they used to break for a lot more, or end up as track day cars. I expect some of those track slags were rolled in glitter when prices went up.

[Wh1t3Kn1ght]

OMG must resist - just looking at some of the older updates, I haven't even considered upgrades for my engine. Busy doing other jobs on the car!

Don't suppose you still have one of those engines for sale? (not that I have anywhere to store it)