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Engine build progress

Fantastic work and true dedication to the marque. Look forward to seeing it at a Donington track day? TTM, how do you get those pics onto the forum? I've got pics of the rear rebuild of mine that I want to show, mainly the pics of the rear very rusty brake lines, fuel pipes and spring plates for the 968 guys to look out for now. Cheers Dave
 
ORIGINAL: xenon What is the purpose of wrapping the manifolds - is it just heat shielding?
Yes. As we found out the engine bay gets much less hot with wrapped manifolds. I also like the idea of fuel lines hanging above being less exposed to heat though this is probably being overcautious. Today we cleaned and refitted the intercooler, completed the home-made J-boot between the MAF and the turbo, sorted the usual mess under the intake manifold and fitted the latter - it's amazing how much better you feel as soon as the intake manifold is on, just as if fitting this very item tells you the end is near [:D]
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ORIGINAL: David Hooper Fantastic work and true dedication to the marque. Look forward to seeing it at a Donington track day? TTM, how do you get those pics onto the forum? I've got pics of the rear rebuild of mine that I want to show, mainly the pics of the rear very rusty brake lines, fuel pipes and spring plates for the 968 guys to look out for now. Cheers Dave
Thanks for the kind words Dave, I won't be at Donington sorry. I host pictures on a personal webpage, but you can attach a picture in each of your post.
 
Pleased to say all "major" mechanical things were completed today - while I was under the car fitting the exhaust/wastegate Sly completed the intake and modified the connector for the MAF. Instead of simply cutting the plug for the original barn door AFM he decided to open it and wire the plug for the MAF to it, meaning either meters can be plugged if necessary [:)]
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Tomorrow will have to purchase a new battery, some fluids, refresh the starter motor, complete the wiring for the Piggyback/Zeitronix (we're about half way), open up an old snorkel, turn the key and treat ourselves with a well-deserved load of beverage regardless of what happens - fingers crossed... [8|]
 
Nice ! Don't forget to prime the oil pump before starting ! You're lucky to have a new camera doing nice videos ;)
 
Thom, as always a superb instalment - this is better than Neighbours, even when Kylie was in it! Are you keeping the stock snorkel to the air box or have you a modified on up your sleeve? Also the exhaust manifold wrap - can you wrap the manifolds with them installed in the car or do they really need to be removed and off the car? In theory the wrap should also aid quicker spool up as less heat is lost from the exhaust gasses between the cyl head and the turbo, so they're not just there for insulation. Also which MAF solution are you going for? Vitesse, SciVision or Standalone? Cheers, keep up the good work.
 
I feel quite sheepish now as contrary to what I expected we did not get to start the engine today. We have some sort of excuse though - going shopping on a saturday afternoon (oil, battery, etc) is not the best idea as we wasted much time in the traffic jams and got back in the garage not earlier than 6pm. At least we got to complete the wiring loom, so theoretically we just have to put the fluids in and turn the key, which is likely to happen tomorrow [:)]
ORIGINAL: sawood12 Thom, as always a superb instalment - this is better than Neighbours, even when Kylie was in it! Are you keeping the stock snorkel to the air box or have you a modified on up your sleeve? Also the exhaust manifold wrap - can you wrap the manifolds with them installed in the car or do they really need to be removed and off the car? In theory the wrap should also aid quicker spool up as less heat is lost from the exhaust gasses between the cyl head and the turbo, so they're not just there for insulation. Also which MAF solution are you going for? Vitesse, SciVision or Standalone? Cheers, keep up the good work.
Hi Scott, We will be trying another type of modified snorkel, made possible with the fact that we threw away the AC on my car and consequently have some extra room to play with - will post some pictures when it's done. I think wrapping the manifolds correctly with them in the car would range between very difficult and simply impossible. I know that wrapping the manifolds is supposed to help increase spool, but on our cars that really wasn't done with this in mind and the location of the turbo is just silly. I ended up buying a Vitesse MAF/MAP as I couldn't find someone who could provide me with DME/KLR chips suitable with my custom turbo. Friends Sly and Marc have reported good results with the Vitesse MAF. I also spent some time with Sly tuning his car with the Vitesse software and it helped making the decision. As of now I'm just not too sure about the boost solenoid from Vitesse as setting it requires connecting the laptop to the car, which really is not great in terms of ergonomics. Marc spent much time setting a correct boost ramp and his car acted quite funny under wide open throttle until he got it right.
 
Not anymore Paul as I'm pleased to say it started a couple of hours ago [:)] [link=http://mapage.noos.fr/tjmm/3019/demarrage.avi]VIDEO[/link] (please right click > save as) We primed the oil pump and filled the oil radiator (we primed the turbo just before installing the intake pipe), then cranked the engine until it built oil pressure then started it for good. After it went through a complete heat cycle we replaced the oil, in which we did not find any worrying bits. I suppose we will find some in the next oil change once the first 600 miles will be done. Now have to tidy the electrical mess in the passenger seat area, put back the wheels on and go for a drive. Not quite totally relieved yet as I think the first miles will be the most important for the health of the engine - I plan to run it in the old way but if you chaps have any suggestion on this matter I'm all ears [8|]
 
Good news on a great job Thom!! Congratulations on a fantastic build and best of luck with it's future. Thanks for a really informative thread too.
 
Great noise, very well done on such a project. Look forward to the road test and then the track test! Again really well done Mike
 
ORIGINAL: TTM I plan to run it in the old way but if you chaps have any suggestion on this matter I'm all ears [8|]
Off boost for the first 500 miles, then gradually dial in the boost and let her rip [8D] .....and then try to get across the channel and up to Chester for our Dyno Day [;)]
 
Did about 60 more miles today, every gauge shows what it should. I'm surprised though how more quickly than the 2.5 it warms up - it actually warms up as quickly as my S2. Probably caused by the fact the 104mm block contains half as less coolant as the 100mm block? Temp in the engine bay after shutting down the engine seems to be higher than with a 2.5 too, I dare not think how hot it would be without the wraps on the exhaust manifolds. Here is a final picture of the finished article :
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Haven't fitted back the Heigo strut brace yet as the engine seems to be higher than before (the brace adjustment was tight but fine with the 2.5, with which we found out when taking it out that the right engine mount had collapsed) so might end up machining the strut brace slightly to make it fit. Running an unmodified snorkel that came with the new airbox for now, will complete the new "special" snorkel in the coming weeks if I'm bothered - just so pleased with it so far that I don't feel working on it anymore [:)]
ORIGINAL: Diver944 .....and then try to get across the channel and up to Chester for our Dyno Day
Hmmm... Is it me or Chester seems to be a good way up north? The budget doesn't look too good for now, would have been great to meet up but I'm afraid it will have to wait until I can afford a trip in GB back again [&:]
 
Did 700 miles so far, off boost and revs below 3000rpm for the first 300, alternating light throttle with overrun and avoiding constant revs as much as possible, then did the next 300 the same way but then below 4000rpm, then replaced the oil used for the running in with a proper one. Was pleased to find no metallic bits in the old oil. Began to open the throttle a bit and make some boost in the last 50 miles and I all I can say is just [:D][:D] - on this matter I would like to thank publicly Simon Peckham who provided me with a turbo that makes the engine deliver its power exactly as I wanted. It's going to be a monster once I set the boost higher! Am not too confident yet on opening the throttle to the max though the engine works perfectly, and I suppose taking it easy for another couple of thousand miles would be wise - any opinion on this? Also a bit concerned with possibly "washing out" the cylinders with fuel if I drive it too sedately... Also, oil consumption has remained nil since start up.
 
Sounding very good so far Thom [:)] A few thousand miles sounds pretty conservative (but I can understand your caution after all this time). Jon let me have full revs and boost (at 15psi) after 1000 miles as long as the AFR's stayed between 11:1 and 12:1 when on full boost
 
Thom, I am in awe. Sounds great and I hope that when you really do let the reigns of completely it exceeds your expectations because after undertaking such an enormous task you deserve no less. And don't worry about the rolling road day - if you can't make the one in Chester then we can arrange the next one to be in France!
 

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