944 S2 Repair

[sgl1966]

Took the head of this morning and initially looked good but then tried removing piston to reveal the extent of damage to that piston. At least the head looks ok with the piston having just kissed the head and as far as I can see and feel so far, the crank escaped relativley unharmed although everything will be checked and measured if it is used again.
Managed to get the gearbox and engine out today with the new one ready to be lifted up and bolted in place in the morning. Really feel my age tonight with all the crawling underneath this lot involves.
Anyone got a spare 968 piston for sale ? Simon

[pauly]

What pistons and cylinder material are you using in the next motor ?

[sgl1966]

Hi Pauly, got steel liners and Je uncoated pistons in this one and after market rods with K27/8 .

[pauly]

How about the engine management ?

[sgl1966]

I am using Tom's Augment ecu, which works for both engines if you use the turbo bellhousing and ref/speed sensors. Clutch is a sprung 6 puck I had made.
Engine and torque tube in, just need a couple of hours to refit gearbox and new exhaust. Will have to redo the throttle cable bracket on the inlet manifold as it is just catching the bonnet. But apart from that all looking good.

[pauly]

Look forward to hearing how it goes, turbo might be a bit small though ?

[nicksonmsport]

shame to hear the engine went bang. look forward to seeing what the 3 litre 16v will do though! inlet manifold looks good lol!

regards
nick

[sgl1966]

Thanks Nick, I will whip the inlet manifold of and bring it up to make a couple of small changes, but does look good.

Pauly, the turbo was available at a good price and there is a dutch guy running the same set up for racing achieving 473 @ .82 bar ("porshe 944 turbo assen" on you tube) . Never intend to go more than 1 bar as it will be past its efficiency range.

[R/E 951]

Simon,
Sorry to hear of your misfortune, That really did go badly wrong. Did you do any power runs to see what sort of power the car was producing? or would you have any idea from driving it on the road?

But every cloud has a silver lining and your 16v engine really looks the part, the manifold especially. I look forwards to hearing what results you get from the engine with the 16v head. 16v's do seem to be able to make plenty of power.

Also would like to hear how the clutch performs as I don't care much for a lot of the aftermarket options and have a feeling mine isn't going to just keep holding much longer .

Good luck with the new engine

Robert

[sgl1966]

Hi Robert, sorry to take so long to reply , family holiday, on a beach secretly wishing I was back in my garage unbeknown to my wife.
Unfortunatly no power figures were recorded, but it was bloody quick on the road before going pop. Hope to get the the final bits on the weekend and start it. I have started the other 3 litre 8 valve turbo build so still hope to be able to compare engines.
I have also fitted the 3" ASS stainless exhaust which I have to mention fitted perfectly.

[sgl1966]

Because its not standered everything takes longer to do, get made or altered but finally thought I was going to get the car started today. But after filling her up with a cheap mineral oil and water thought it prudent to test the fuel rail after modifications to check for leaks before cranking her over. By passed the dme and with the fuel pump running a steady stream of fuel sprayed out of a pin size hole. After hearing stories of these fuel rails suffering with cracking and with solid engine mounts I have invested in a LR billet fuel rail, just got to wait for it to turn up, more waiting !

[R/E 951]

Great looking engine bay!
Love that manifold hope I can make mine look as well on my car.

Reading about your fuel rail is giving me second thoughts about fabricating a custom set of stainless fuel and water rails for my car. Fuels definitely not something to be messed with!

What top mount setup have you got? Also where did you get the strut brace it look very period Porsche. Its very like an original 964 Carrera RS strut brace I've seen.

Has the new manifold opened up much room for the turbo?

Keep up the good work
Robert

[sgl1966]

Hi Robert,
Thanks for the comments, if I had the time I would probably had a fuel rail made as people like Demon Tweeks sell just the billet rail but I have got impatiant to get her started .
The top mounts are a solid monoball set up but unfortunatly without camber adjustment and as for the fuel rail, it was a fortunate purchase of a friend, unknown make but really good quality and adjustable.
Very pleased with how the manifold turned out with plenty of space around it even to get the brake booster heat shield on. There is a good 40mm clearance between the turbo and manifold even with the larger k27 housing so plenty of room for an upgrade ! I do have an LR61 on a 2.5 that will be swapped over if this turbo dissapoints.
Simon

[sgl1966]

Robert, just read your thread and the quality of your work is outstanding, really looking forward to seeing how the ITB turnout, I have been toying with the idea for a future build .

[sgl1966]

Fuel rail turned up from Lindsey racing. Very impressed that I ordered it tuesday from usa and its being delivered to my door on friday morning, not only that the rail itself is a very nice item with some decent wieght about it. No more worries about a cracked rail spraying fuel onto the exhaust manifold. So hope to get this started over the weekend.