blau928

Hi Hilton,

This will be done. I am getting the fonts to the engineer next week to incorporate into the top cover. I think it will be a 1-2mm relief, and can be scribed with a milling machine. Inspecton shops will not be able to tell if it's raised or sculpted, and uses the porsche font..

Hey a little sneaky never hurt.. Besides, the rest of the motor will still be all porsche, just have a silghtly different manifold setup.. Dual intake air filter tubes and all..

Imo000

Any update on this?

blau928

Hello all,

I have been gone for a long time, and am now back and will be posting pictures of things and the car, as i have decided to finish it hopefully by summer. (I am going to do it all myself, as I can find nobody that can do what I want done to my specs.) Anyway, past is past..

Also did a TB WP as the car was sitting for several years (2) and only drove to the front gate and back 5 times...

I have made some improvements to the cooling system (Radiator, oil, and trans fluids) and crankcase ventilation by adding a vacuum pump and pro vent. I also installed a new Parallel flow AC condenser and have partially plumbed the AWIC radiators as well..

I have to RR the IAC as well over the next week or so, and will post pics as time permits for those who are interested.

I see there have been many things on 928 - RL that changed, but many are the same..

Thanks,

Imo000

Has anything actually been made from the CAD drawing?

blau928

IMO

All the cad drawings have not been made yet. The intercooler bits are done, I have to finish the SC mount plate, the base head plate, the injector runners, the throttle assembley and the IC outlet. I will be doing bits starting in mid may, and I will most likely cast the injector blocks and runners.

I received some very substantial prices to mill the blocks from billet, as they have very complex curves inside the runner, and hold two injectors per cylinder. I am also exploring composite 3d printing in some special polymers to keep the weight down. I will post pics once the bits are done. I will be making a mold master in mid may from abs as a 3d printed part. I will post pics once that is ready. (I have a business trip that will have me gone until mid may...)

Also, I have lost confidence in many of the "expert machinists" that are supposed to be able to do stuff with a CAD file..

Anyway, lots to do, but progress is being made considering everything was on the shelf for 2 years... The finished product will look like Sean's yellow car, but without all the welded bits, and be on a 32V motor.

I'll post some pics of the recent updates soon.

Thanks,

blau928

Added some things the past few weeks.. Pictures read from left to right..


1. Modified the AC to use a parallel flow condenser, and moved the pressure switch to a more convenient spot. There is a hole under the hood stop left of the pressure switch that I can use to check the AC drier, which has been moved and is off to the side of the condenser but further forward. (It was a major pain to fit this..)

2. AN 12 oil lines from the engine block to the laminova oil and trans cooler (The lines still need some mylar tape for the sleeves protecting the kevlar hoses, and Trans has AN-6 lines now. Also need to install the oil filter..)

3. Laminova Engine and trans cooler with the fan shroud on the rad being a single 3600 CFM Spal. There are also two 1200 cfm Spal fans on the AC condenser, all wired to the fan controller.

4. You can see the AC Condenser, the Radiators for the AWIC system, and the custom C&R radiator for the motor all fit in the stock location, and minimizes space for other things.. (I think it looks stock..)

5. Top view of the Condenser, fans, AWIC radiators, and engine radiator with new fan shroud. The AC fans come on under load, so they will cool the AWIC system as well as they are wired into the fan controller.

6. There is now a vacuum pump replacing the airpump that pulls crankcase vaccum and vents to a Mann Provent 200 and an oil drain to the sump and a fresh air return to the intake before the MAF. I am plumbing the oil return to the oil pan block off plate on the front of the motor..

7. Underside view of the AC condenser, holes for the AN-12 lines for the AWIC plumbing (radiator lines). (I had to modify the crash bar to get it all to fit properly.... another pain in the ***)


Cheers,

justaguy

Any thing I can do to help just let me know.
You might want to consider mounting the injectors and fuel rail out board

Modifiying the water bridge can be problamatic I spent a ton of time getting the flow right on the modified water bridge.

Overheating is the single biggest problem with my set up at the moment. I can run it on track at about 75% and it's ok but if I push it to the limit it overheats after a few laps.

blau928

Hi Sean,

Thanks for the offer. I do have questions about the yellow car's setup.. I can probably send you a PM, as it's technical, and relates to the Motec you are running, as I have an M8 that I need to configure.. I will also have data log questions that would be really helpful..

About the heat you are experiencing, my version of the water bridge # 1 keeps it stock, but uses different fittings.. They are 2 AN-16, with the option to tap into the 3rd head cooling port on cylinder #8 by tapping the block off plate.. I think the cooling will be fine with the bigger radiator and very good shrouding..

I also have a design sketched for a reverse flow cooling option, as I have a 928 waterpump modeled in CAD, and will explore this later..

I noticed that your AWIC seems to use a motorcycle radiator, and I'm curious about the coolant you use as well..

About the injector rails, I modeled all of the bits in CAD, and made sure there are clearances for all the parts, so I am not worried about clearance issues on the SC assembley at all.. (Solidworks is pretty good about this..)

I may have some suggestions on the overheat issue once I can look at the datalog if you have it enabled in the Motec..

Anyway, good to catch up on Rennlist.. I had hear of your car as the mythical beast when Hatfield had it.. Now I see it in the pics, really cool stuff.. I can't wait to finish mine..!

Cheers,

blau928

Pics left to right...

1. The plumbing has been done for the Provent drain to the sump

2. The vacuum pump inlet is also now plumbed with an AN-12 fitting to a metal oil filler that was sitting around for years.... I'll be R&R'ing the plastic oil filler with this metal one..

As the new TB and WP are in, next should be the fuel lines re-route with AN-8 lines, and the Power steering reservoir relocate, and the car should be ready to start after R&R'ing the IAC as the one on the car is shot..

I have modified the water bridge, and will post pics later, as that should be installed sometime this week as well...

That was my Sunday....

karl ruiter

I use have used ProtoLab's Online CNC service Firstcut.com with good results. The only input they take is 3D cad files. I have sent them many solidworks files and gotten good parts in both plastic and aluminum. Takes about 24 hours too, and you can normally get quotes in an hour or so. Not sure they can make parts big enough for your needs, though.

blau928

Hi Karl,

Thanks for the suggestion.

I got some quotes from Protolabs, and have spoken to them and several others. It seems prices have gone way up from what I was quoted 2 years ago. All the pieces are in Solidworks, and I only have 3D CAD files..

(Some machinists wanted 2D drawings of the injector runner/block... I almost fell over when they told me that they could make a compound loft with decreasing radius by hand after i spent all the time drawing stuff in CAD for very specific reasons..)

Anyway, like I mentioned, I will most likely cast the runner blocks after 3D printing the mould..


The other bits will be done on a 4/5 axis...

Best Regards,

rgs944

cool project

Tony

Glad to see you back!

Ive always wanted to see your project get finished....looks great in CAD!

What size blower? 2.0? 2.2?

blau928

Thank you!

blau928

Hi Tony,

Good to be abck as well..!! Thanks for the support!!

I have an Opcon/Autorotor MX422 (2.2L) I will start with that and see where it leads.. The case is the same size as a 2.4L, so I know that fits as well...