Show full size 924Board.org
Discussion Forum of 924.org
 
 FAQFAQ   SearchSearch   MemberlistMemberlist   UsergroupsUsergroups   RegisterRegister 
 ProfileProfile   Log in to check your private messagesLog in to check your private messages   Log inLog in 
 Technical FAQ924 FAQ (Technical)   Technical924 Technical Section   Jump to 924.org924.org   Jump to PCA 924 Registry924 Registry

German Godzilla. The creation of a (2-tone) Green Monster...
Goto page 1, 2, 3 ... 11, 12, 13  Next
 
Post new topic   Reply to topic    924Board.org Forum Index -> Performance Upgrades
View previous topic :: View next topic  
Author Message
WEASEL149  



Joined: 19 Aug 2005
Posts: 592
Location: UK, Sheffield

PostPosted: Sun Mar 17, 2013 9:15 am    Post subject: German Godzilla. The creation of a (2-tone) Green Monster... Reply with quote

Thought I'd start a build thread on here for what will hopefully be the rebirth of my 932, affectionately known as 'Bogey'.

She's a two-tone green car previously owned by both Colin Belton (930 Motorsport/Ninemeister) and Andrew Mearns (Auto Classica/Gmund Books).

The car has served me well for 12 years. I made some mild modifications to her when the head gasket blew after 2 years of owning her.

I fitted a 951 intercooler. The block was 'O' ringed and the head was clamped using Raceware studs.
Crank case breathing was improved using a kit that used to be sold by Turbo-Technics and a catch tank fitted.
Wastegate was refreshed and converted to dual port operation using a Blitz dual solenoid electronic boost controller.

This engine then stayed pretty much the same until 2011 when I noticed the car losing some water out of the 944 tank I had fitted.
Tests showed that the car was pressurising the coolant system when it hit 0.5 bar or more so the decision was made to pull the engine before it got worse.

I found a tiny pinhole leak near one of the 'O' rings and eventually decided to strip the whole engine after noticing pitting on one cam lobe.
The result showed all top compression rings were broken. Big-ends and bearings were mint but 3 main bearings didn't look too good.
The main cap that has the 2 smaller 12.9 bolts in was cracked so I decided to source some parts.

I ended up buying a complete NA engine, another NA short engine that had been raced a couple of times and a recon crank @0.25mm.

Previously I have kept the car looking reasonably stock but this time I decided to go all out with the engine at least.
I decided early on that the standard fuel and ignition system had to go and planned on full engine management.

Here is the car as it was before it was stripped down:-









_________________
1979 UK 932


Last edited by WEASEL149 on Fri Jan 16, 2015 7:41 am; edited 1 time in total
Back to top
View user's profile Send private message
WEASEL149  



Joined: 19 Aug 2005
Posts: 592
Location: UK, Sheffield

PostPosted: Sun Mar 17, 2013 9:46 am    Post subject: Reply with quote

Lots of reading and research ensued. The more reading I do, the more I want to do to the car so it has gone a lot further than I originally planned.

My problems in general are budget, which is tiny and also work which takes up too much time, so this build has become a bit drawn-out.

I looked at various management solutions and decided on VEMS - mainly inspired by Raceboy's success with this ECU.
Also a used VEMSV3.3 with full wiring loom came up for sale on fleabay, so I bought it.

Plans so far are as follows:-

1)Engine management.

2)Change 951 intercooler for water/air chargecooler.

3)Fabricate new inlet manifold.

4)Fit Holset HY35 Turbo with new tubular exhaust manifold and a new external wastegate with screamer pipe.

5)Thermal management - larger more efficient alloy rad along with a large oil cooler.

6)Make selected upgrades to engine internals during this rebuild.

7)Fabricate new cold air intake to go with the rest of the new inlet system.

8)Custom cam.

9)New exhaust system - at least 3" from turbo back.

***Edited 6th Jan 2014***
_________________
1979 UK 932


Last edited by WEASEL149 on Sun Feb 23, 2014 8:08 am; edited 2 times in total
Back to top
View user's profile Send private message
RC  



Joined: 25 Mar 2007
Posts: 2624
Location: Australia

PostPosted: Sun Mar 17, 2013 10:00 am    Post subject: Reply with quote

That`s quite a nice looking and original car Wes.

Just as well you got another block, way to go. Same with proper engine management, only way to go these days.

Good luck with the credit card as there`s no luck involved with engine building, just skill & $$$.
_________________
World`s quickest 924 2L slushbox

Allan @ DTA wrote:
I have no issue with superchargers, they are for guys who want to drive a car rather than talk about horsepower with their baseball cap on backwards
Back to top
View user's profile Send private message
WEASEL149  



Joined: 19 Aug 2005
Posts: 592
Location: UK, Sheffield

PostPosted: Sun Mar 17, 2013 10:55 am    Post subject: Reply with quote

RC wrote:
That`s quite a nice looking and original car Wes.

Just as well you got another block, way to go. Same with proper engine management, only way to go these days.

Good luck with the credit card as there`s no luck involved with engine building, just skill & $$$.


Thanks mate.

Very true what you say about engine building. I'm a machinist by trade and hate entrusting any machining work to others but have no choice.
No doubt I'll be double-checking all their sizes when it comes back
_________________
1979 UK 932
Back to top
View user's profile Send private message
WEASEL149  



Joined: 19 Aug 2005
Posts: 592
Location: UK, Sheffield

PostPosted: Sun Mar 17, 2013 11:44 am    Post subject: Reply with quote

I realise I've posted various pics in other threads but thought I would collect them here.

First up are the velocity stacks for the new inlet manifold. Full radius and measure 74mm across the bell mouth then 46mm I.D. at the top, tapering down to 38mm at the bottom with a length of 170mm. The best I could find 'off the shelf'.



Here is the flange for the head:-


_________________
1979 UK 932


Last edited by WEASEL149 on Mon Feb 24, 2014 2:12 am; edited 1 time in total
Back to top
View user's profile Send private message
WEASEL149  



Joined: 19 Aug 2005
Posts: 592
Location: UK, Sheffield

PostPosted: Sun Mar 17, 2013 11:49 am    Post subject: Reply with quote

A slight increase in the size of the oil cooler - a 50 row Setrab unit about the same size as the one fitted to the F40.




_________________
1979 UK 932
Back to top
View user's profile Send private message
WEASEL149  



Joined: 19 Aug 2005
Posts: 592
Location: UK, Sheffield

PostPosted: Sun Mar 17, 2013 11:54 am    Post subject: Reply with quote

To keep the engine cool I managed to obtain this - 4 core, 70mm thick Pace radiator with a low profile Kenlowe:-




_________________
1979 UK 932
Back to top
View user's profile Send private message
WEASEL149  



Joined: 19 Aug 2005
Posts: 592
Location: UK, Sheffield

PostPosted: Sun Mar 17, 2013 12:09 pm    Post subject: Reply with quote

Fuel rail, courtesy of Ford - from 1.8L Duratec Mondeo.
Just needs modding for return.



This shows it lined up against my spare head


_________________
1979 UK 932
Back to top
View user's profile Send private message
WEASEL149  



Joined: 19 Aug 2005
Posts: 592
Location: UK, Sheffield

PostPosted: Sun Mar 17, 2013 12:26 pm    Post subject: Reply with quote

630cc flow-matched Siemens Deka high Z injectors shown with 034 Motorsport alloy injector bungs.
I need to get new photos as I've modified the bungs slightly by shortening them on a surface grinder.
I also cut a little more thread in the head with an M24 tap so they sit a little further in.

Finally I'll be drilling the injector holes out in the head and enlarging them slightly. Using Trig and knowing the injector spray angle, it's easy to work out the hole size needed for unimpeded injector spray.




_________________
1979 UK 932
Back to top
View user's profile Send private message
peterld  



Joined: 10 Dec 2006
Posts: 682
Location: Noosa Heads QLD Australia

PostPosted: Sun Mar 17, 2013 12:37 pm    Post subject: Reply with quote

WOW!!!!
_________________
80/81 932/8 ROW
Back to top
View user's profile Send private message Send e-mail
WEASEL149  



Joined: 19 Aug 2005
Posts: 592
Location: UK, Sheffield

PostPosted: Sun Mar 17, 2013 12:50 pm    Post subject: Reply with quote

Forged 2618 Omega pistons with coated skirts.
Aiming for ~8.5:1CR.




Shown side by side with stock RoW S1 piston


_________________
1979 UK 932
Back to top
View user's profile Send private message
WEASEL149  



Joined: 19 Aug 2005
Posts: 592
Location: UK, Sheffield

PostPosted: Sun Mar 17, 2013 12:53 pm    Post subject: Reply with quote

peterld wrote:
WOW!!!!


Yeah I know, you can't contain your excitement
_________________
1979 UK 932
Back to top
View user's profile Send private message
peterld  



Joined: 10 Dec 2006
Posts: 682
Location: Noosa Heads QLD Australia

PostPosted: Sun Mar 17, 2013 2:53 pm    Post subject: Reply with quote

And I love weapons-grade hardware!!
_________________
80/81 932/8 ROW
Back to top
View user's profile Send private message Send e-mail
Carrera RSR  



Joined: 08 Jan 2010
Posts: 1535
Location: Somerset, UK

PostPosted: Sun Mar 17, 2013 9:09 pm    Post subject: Reply with quote


_________________
1980 931 - forged pistons, Piper cam, CGT turbo, 951 ducted FMIC, custom intake, Mittelmotor dizzy & cam pulley, H&S exhaust, GAZ Gold, Fuch'ed, Quaife LSD
Now www.924board.org/viewtopic.php?t=34690
Then www.924board.org/viewtopic.php?t=31252
Back to top
View user's profile Send private message
morghen  



Joined: 21 Jan 2005
Posts: 7808
Location: Romania

PostPosted: Sun Mar 17, 2013 9:54 pm    Post subject: Reply with quote

love that car !
keep going !
_________________
red 924 and not red 924
Back to top
View user's profile Send private message Visit poster's website Yahoo Messenger MSN Messenger
Display posts from previous:   
Post new topic   Reply to topic    924Board.org Forum Index -> Performance Upgrades All times are GMT + 11 Hours
Goto page 1, 2, 3 ... 11, 12, 13  Next
Page 1 of 13

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum


Powered by phpBB © 2001, 2005 phpBB Group