944 S2 Repair

team44 · Post by **team44** » Tue Jul 08, 2014 12:27 am

looking good,,bring it out in August 4th at silverstone track day...strech her legs
D

nicksonmsport · Post by **nicksonmsport** » Wed Jul 09, 2014 6:12 pm

hi simon had a little play this afternoon with your bits and bobs. I need an engine mount and the turbocharger to ensure the turbo mount is in the correct place for the exhaust to meet up. give me a shout, cheers

nick

sgl1966 · Post by **sgl1966** » Thu Jul 10, 2014 4:09 pm

Took car to garage this afternoon for mot and to fix a few bits I have not the patiants for ( side window bottem rubber !!) and while it is in there got the other block out to start building this up at the weekend.
After previous disscusion about windage holes, I have decided to leave it as is. As can be seen in the photo there is ample room to get my fat fingers between the bores and it is not worth the risk or hassle to enlarge these to gain an extra 5mm.
Nick from Nickson motorsport is doing a superb job cutting and welding up the inlet manifold and altering the exhaust flanges to fit the crossover pipe to the s2 exhaust manifold. should have these back next week.

sgl1966 · Post by **sgl1966** » Sun Jul 13, 2014 9:37 pm

Well started on reassembly of the 16 valve engine today. Not very exciting but thought i would post some photos up anyway, for reference if nothing else.
Even though i have had the crank polished we first checked the run out which was minimal. We then manually honed the bores to the finished size. When the liners were put in, it was finished to +30 thou even though we knew we needed +50 thou due to the expansion of the pistons. This allowed us to finish each bore to each piston by hand to make up for any discrepancy between them. Piston rings were then filed to fit and conrods connected. These really are good value and quality.
Have to wait till next weekend now but hope to get a good two days on it.

nicksonmsport · Post by **nicksonmsport** » Mon Jul 14, 2014 10:07 am

give me a call simon before you come down. I just need to offer the block/head back together to make sure the throttle body is at right orientation before welding it on, so not quite finished yet.

nicksonmsport · Post by **nicksonmsport** » Mon Jul 14, 2014 10:08 am

will be some point this week. just got to get this m3 out the way over next couple of days first

cheers
nick

nicksonmsport · Post by **nicksonmsport** » Fri Jul 18, 2014 9:21 am

tried to get in touch with no success. dont come down today mate im slightly behind, will all be ready for you early next week.

cheers
nick

sgl1966 · Post by **sgl1966** » Wed Jul 23, 2014 12:26 pm

A few photos of the completed manifold on a dummy engine Nickson motorsport have completed for me . Very pleased with the outcome.
I believe that now Tim has shown how and you have Nick with his welding skills on this site , the 3 litre 16 valve turbo is a viable option to people. You still need to sort out the rod and piston issues as with the 8 valve but there a lot more twin cam heads out there than the elusive 2.7 heads. Nick has also altered the flanges on the crossover to match the s2 manifolds and as can be seen by the photos there is plenty of room for the k27 I will be using. Nick also altered the fuel rail and added the oil pick up tube support I sourced from Paragon. Not sure how to finish the manifold yet,probably just aqua blasted and a protective coat as I like the bare aluminium look.
Hope to show this installed on the rebuilt engine next week.

sgl1966 · Post by **sgl1966** » Fri Jul 25, 2014 6:49 pm

Had a day of work today so we carried on building the engine up. Got the crank and pistons in place. Piston rings were a bit of a struggle first of even with ring compressor, so much stronger than originals.
Thought I would post a couple more photos to show the oil pick up tube support bracket. Great piece of insurance, really gives strength to the tube. Had it tig welded to the pick up. The engine looks clean from the amount of sweat dripping of my head today.

nicksonmsport · Post by **nicksonmsport** » Sat Jul 26, 2014 10:55 am

looking good, look forward to seeing the finished product, and results from both the 3l 8v and 16v engines. be good to compare the differences between them both.

keep the pics coming

nick

sgl1966 · Post by **sgl1966** » Sat Jul 26, 2014 5:15 pm

Thanks Nick, here are a few photos of todays effort. Couldnt resist offering up the manifold and exhaust again to check clearances again. As you see there is so much room even with the k27, need a bigger turbo ! Apart from that carried on assembling everything else. Got held up as I forgot to have the balance shaft casing tapped, didnt fancy doing this as it is an odd size tap and as these are line bored didnt want to mess it up. So had to work round that and some parts will have to be refitted when that is done.
It is begining to look really good and i am so pleased i took the time to have everything cleaned and plated, makes working on it a pleasure. Unfortunatly holiday beckons so this is going to have to go on hold for a couple of weeks.

sgl1966 · Post by **sgl1966** » Thu Aug 21, 2014 4:46 pm

Well we just about finished the build of the 16v turbo engine today and very pleased with the outcome. Just hope it runs as good as it looks. Couple of minor issues to sort out, modify aos filler neck, adjust dipstick fixing and rotate and reweld goose neck as it is hitting the manifold. Put in new slipper pads and chain and did the basic cam timming with new belts and water pump etc.

nicksonmsport · Post by **nicksonmsport** » Thu Aug 21, 2014 9:15 pm

Looks awesome!!

Have you had the inlet blasted? Looks smooth.

Cheers
nick

robmal · Post by **robmal** » Fri Aug 22, 2014 7:34 am

Nick

I'll be wanting you to make me one of those supra hybrid chambers one day - I'm saving hard!!

Keep up the good work guys, its very motivating for us all - Watching this build and loving it

All the best

Rob

sgl1966 · Post by **sgl1966** » Sat Sep 13, 2014 5:04 pm

Been busy with work recently and still not got the car back from garage after some minor body work but have managed to do a few things on the other engine. Been wrapping the exhaust manifolds to stop my fingers getting burnt but my god that stuff makes you itch ! Worse than roof insulation. Used lockwire to stop it fraying. Had to alter the oil filler pipe due to the manifold and relocated the idle control valve with a p-clip under the manifold.
Decided to go with these solid mounts after the semi solid mounts (dibed ?) turned up but the bolts would not go through the mounts with out drilling them larger. Did not fancy that in case I go back to standered, so be warned if you order these. The car is only used to go to a track and back and the odd blast up the road, but it will be intresting to see how bad these affect the car on the road.
Main job has been refurbing the torque tube with new bearings and powder coating. Not that bad a job to do and relatively cheap, £26 for bearings and £ 20 for powder coating the tube. An unorthodox method of removing the bearings with a 3" round fence post but all back in safely and so smooth. Just waiting for flywheel and clutch to come back, going with a sprung sintered 6 puck, hopefully this week and of course the car !