I found some shorter muffler, we'll see if I can use them.
The exhaust is not final anyway, it's just to be able to move it without telling all my neighbours!

 

I'm waiting on new mufflers, hopefully they will quieten the fckr for now until I can make a real exhaust !
By the way, single or dual exhaust ? Single 3" is easier, and cheaper than dual 2.5" !

I cleaned up the garage !





I spent all afternoon trying to figure out where to put the power steering pump... screw that, it'll be in the trunk !

I wired the battery switch. still need to drill the battery tray lid for it.



I started machining the small bit to attache the throttle cable to the throttle body plate, but I don't have small enough drill bits...



Yesterday, while cleaning I found this :

Still working, I'll use it for cold starts.


I received a quote to paint the wheels... they are BAD !




And found the best prices for the R88r. But I also found Sport Cup 2's tires for only 16€ more... I don't know what to get, both are awful on the wet anyway. The Cup2 don't last really longer than the R888R, but the Toyo are definitely stickier...

 

Soooo... I bought a new engine !
A M28/21 !
1550€, which is cheap for one here !
We'll see exactly what I do with it. N/A or supercharged ?
Probably supercharged... I like superchargers !


Yesterday I made the hard lines for the power steering :







Next, the rear part, and the wiring of the pump !

I prepared the wheels for paint :


Good thing I'm a Porsche Tech, I found the old RDK tool



I'll plug the holes with aluminum plugs.





We had another 928 at the shop too !



It wasn't scheduled for me, but I still ended up doing the alignment on it and the test drive

Ben

 

Nice work Ben!!

 

Thanks


Yesterday I worked on it a bit !




I ended up moving them forward a bit...

Then I made the new power steering line holders !





And finally I finished that off !




Next big things are getting a proper intake and air filter, and mounting the oil cooler securely.


The engine I bought, advertised as a 4.7L M28/21... ends up being a 5.0L... but they told me it's a M28/45, which to me doesn't exist ? It's 41, 42, 43, 44, 47 and 49 right ?
If it's a US 5.0 I'll make a hybrid with 16 Euro heads, and if it's a euro 5.0, I'll just use it as is !

 

Update !

I tested the RDK plugs prototypes...

They fit perfectly !
No I'll make them in aluminum.

I had my Nardi wheel redone to replace the carbon wheel.






So... The new engine I bought is NOT a 5.0... It is a 4.7L M28/22 !
A broken M28/22

More on it later !

I'm redoing the seat mounts to lower the position... I don't fit with my helmet on...


I'll also make some feet plates.

So... about that engine ?

I received it Wednesday !




I don't think it was running when it crashed...



With the MaxxECU I'll be able to use the stock toothed wheel.

In the truck, going home !


Arrived !



Ok, now it's the less fun part ...

Removing the bottom part of the airbox revealed this !


Yeah, sand in the engine ! Nice !

After removing the intake it looked like that...

Rust and sand !

In the intake runners ?




Crap !

Removing the bank 1 camshaft holder, the camshaft doesn't turn all the way round in it... probably bent ? I'll see, no big deal though.

Behind the water pump !


Ok, right now it looks really bad :/

But I kept on taking it apart !

After vacuuming the intake ports, most of the stuff is gone !




Under the heads, aside from the dirt, the cylinder bores are like new !




I moved back to the heads :




Once out, most of the crap on the valves is rubbed off with a finger, and the light surface rust won't be a problem !
The valve guides had no play at all !


Now, what I want to do with it ?

I think I'll stay N/A, for simplicity and reliability reasons...
Aside from the normal maintenance items including all the seals, bearings and controls, the block won't be touched too much.
Windage tray from 928Motorsport maybe ?
Lightweight flywheel, definitely !
I want to make a dry sump system, but I don't place it as a priority.

For heads, re-grinding the camshafts to suit my needs.
I like the idea of the lightweight lifters from 928M, and for the price it's a not a big deal.
The valves have a quite big stem, I don't know if we can save a few grams and improve airflow here yet.

I'll use my intake at first, but I'll probably move to ITB in the future... just because ITB Porsche V8 sounds mean ^^
With MSDS headers.

I don't know how much power and rpm we can get out of a m28/22 engine staying N/A without intensive machining ?
I'm not looking for maximum performance, just a bump in HP and reliability on track.
If I can hang with a 996 3.6 I'll be happy !


That's it for now.
Tomorrow I'll try to finish the power steering and the second head.
I won't do any of the work on the heads, I'll send them to a reputable shop in France


Ben

 

Ben has the hoses from the cambox made any difference to the oil leak? Mine is certainly still leaking. I notice I have very little blowby and a minuscule amount of oil actually goes to the oil separator. I'm guessing the original K-jet set up sucked a lot of the blowby through the system. My air intake always had heaps of oil. When I started the conversion to full EFI I ran a full sized battery earth from the battery to an earth bar, a piece of thick aluminium bar across the rear of the engine to mount all the sensor and ECU earths to. Couple of weeks ago I ran a heavy 12v positive cable direct from the battery through the car to the relay board I made for the Microsquirt ECU and now the main relay gets a clean 12v power supply. I had the 12v battery power coming off the fuse panel previously and suffered some noise spikes that scrambled my tune! The 928 was designed long before ECUs were thought of and the alternator and the unusual cable layout of the 928 are not good for ECUs.

 

Hi !
I haven't run the engine in three weeks...
I've had no problem with sensors so far, but I'm not running the stock alternator and most of the original electronics are gone !


Today I worked on the new engine again...
Both camshafts are broken ! nice...

 

So...

Here is one of the valve once cleaned !




The valve seats aren't great, I'll change them... for the price it's not much ! 3.5€ from Porsche.
Does anyone know the maximum valve guides clearance ?
Intake looks fine but exhaust might be a bit too much...




I cleaned the heads in the parts cleaner this morning



And during lunch I went back home and removed the pistons




And made a box...


Pistons are Ok, the coating is worn on the loaded side, but they look very good otherwise.
Same for the cylinders. Only a very small discoloration spot on one of the cylinder. No big deal, it looks better than a lot of M96 and M97 I've seen ^^
Rod bearings are pretty good too... except one ! So I'll replace them along with pistons rings.

Now, the bad news...
Both camshafts are broken... well, they were not broken when I took them out... but when I went to tape the key to the shaft, they let go...



I'll have to check my prices at work tomorrow... but two camshafts for a M28/22 are gonna be expensive !
928M camshafts might be an option... but shipping from the US will hurt !

I still don't know how the engine would react to what I want to do... I might not like an engine that has a peaky powerband.
Lightweight lifters and stiffer valve springs would help revving a little higher, but would that yeld any benefit in term of power ? Even with an upgraded camshaft.

I still want to run a dry sump system. I'm trying to find a good used two stage scavenge pump... I might ask Mr Raymond Boutinaud directly if he has a spare one he's willing to sell...

And an electric water pump.

I talked to the body shop about my wheels... he said they were trash and had to redo them completely... more €€€

I started a small batch of the RDK plugs I designed, should be here within two/three weeks.


Could be worse, could be two bad turbos on my 997... if I had a 997 ^^


Ben

 

Wow, amazing work!

 

Thanks !

I've made a quote for all the parts I need for the new engine...
I should have LS swapped it
I'm at 4000€ + the engine !

biggest expense is getting new camshafts...
The rest is just small things that adds up to just above 2000€
This car better be good !

 

Update !

So... I found used S 300hp camshafts for 300€ !
I won't have the better 310hp camshafts... but hey, better than nothing !
I found two bent valves, but was able to source two new for cheap.
I'm waiting on them and the heads will go to the machine shop for new seats and guides mated to the valves I provide.

The bloc itself is goo, cylinder bores are fine.
Pistons are OK, a bit of wear on the sides but nothing major, the thermal coating is still there, they just need a good cleaning !
I've been able to source almost all the parts needed for less than 4000€, including the engine ! Not bad after all, even if I end up with less power than expected...

I haven't touched the car much lately :/
I did do that :









I just need to shorten the hoses a bit, they push the lines down.


Since I had to order on design911, and that they have free shipping to Europe for 400€+ orders... I made a 660€ order ^^
Braided brake lines, and all the bushings for the front upper and lower control arms ! Meaning that I better get to work on those because my wheels will be ready in a few weeks and I must be able to set the car down !
Oh, and I still have the rear to do...

Aside from that, I redesigned the seat mounts to lower the position, and I designed a foot rest to raise my feet since slitghly because I have no carpet. And because that was a good reason to have a beautiful aluminum part made
I also design a prototype for the future frame rails reinforcement. we'll see how that goes !

 

So, I got the wheels back !

The previous owner tried to paint them with rattle cans after grindind them with an angle grinder... and the old painted reacted with the new one... they had to paint them twice.

I got the RDK plugs too !
Just need the proper bolts which should arrive during the week.





And... I also got the tires ! Which means I have almost everything to get the wheels back !


I made some template for the frame rail bracings

It fits!


Then I moved to the front suspensions !








Then the back suspensions !



Here they are...


Thank you VolksWagen for that portable hydraulic press !


I also removed the front wheel bearings :O


Next week I'm in vacation, I'll try to get the gearbox out.

At work we're also working on the 565th 911 !
Control arms came back from powdercoating!






Next track day is December 5th... that means... that I'll never make it with the 928 ^^

Ben

 

I have this hydraulic ram kit. Would this do the job you used the silver one for?

 

I don't it would.
This cylinder can have the threaded rod go through to pull stuff off of parts and also press them is depending on how you set it up.
I have a video of it I'll post it