964 Engine rebuild
#137
Racer
Thread Starter
![Default](https://rennlist.com/forums/images/icons/icon1.gif)
Thanks chaps, it will be a slow burner of a project but I am thinking of doing some back to back dyno runs when it is all finished so mapping aside hopefully there will be some factual data!
I thought there must be something more to it - A good friend of mine who has a Moto 3 bike team was showing me their lambda bosses and they are way longer than ours so that the tip of the probe only just protrudes into the tube. It makes perfect sense when you think about it that you don't want it reducing and disrupting the flow of the gasses but that is in a race bike where you are chasing every 0.1hp
Haha, it hasn't been that long!! Do you want me to drop that thing round to Toms sometime so I can take a sneeky peek at his pink project?
Haha, it hasn't been that long!! Do you want me to drop that thing round to Toms sometime so I can take a sneeky peek at his pink project?
#139
Racer
Thread Starter
![Default](https://rennlist.com/forums/images/icons/icon1.gif)
Me? No no no, I did do some welding in college many years ago but my welding never looked like that - If it was me then it would have been welded and ground back to protect my modesty!!
A friend of mine is doing the TIG welding & he is a superb welder - He made up my oil catch tank, all of the ally ducting at the front of my car and the oil cooler itself (below). I can handle the cutting, machining, fitting & general bludgeoning but leave the welding to him!
The bits that are tacked together are just that but I think that because it's all made from ti I think he said he was going to purge the 'X' pipe so cap the ends off and fill with argon.
![Name: DSC04697Small.jpg
Views: 735
Size: 81.2 KB](https://rennlist.com/forums/attachments/964-forum/1205159d1501324672-964-engine-rebuild-dsc04697small.jpg)
![Name: DSC05055Medium.jpg
Views: 788
Size: 225.3 KB](https://rennlist.com/forums/attachments/964-forum/1205160d1501324672-964-engine-rebuild-dsc05055medium.jpg)
A friend of mine is doing the TIG welding & he is a superb welder - He made up my oil catch tank, all of the ally ducting at the front of my car and the oil cooler itself (below). I can handle the cutting, machining, fitting & general bludgeoning but leave the welding to him!
The bits that are tacked together are just that but I think that because it's all made from ti I think he said he was going to purge the 'X' pipe so cap the ends off and fill with argon.
![Name: DSC04697Small.jpg
Views: 735
Size: 81.2 KB](https://rennlist.com/forums/attachments/964-forum/1205159d1501324672-964-engine-rebuild-dsc04697small.jpg)
![Name: DSC05055Medium.jpg
Views: 788
Size: 225.3 KB](https://rennlist.com/forums/attachments/964-forum/1205160d1501324672-964-engine-rebuild-dsc05055medium.jpg)
![Name: DSC05202Medium.jpg
Views: 773
Size: 205.2 KB](https://rennlist.com/forums/attachments/964-forum/1205161d1501324672-964-engine-rebuild-dsc05202medium.jpg)
#140
Technical Guru
Rennlist Member
Rennlist Member
![Default](https://rennlist.com/forums/images/icons/icon1.gif)
I thought there must be something more to it - A good friend of mine who has a Moto 3 bike team was showing me their lambda bosses and they are way longer than ours so that the tip of the probe only just protrudes into the tube. It makes perfect sense when you think about it that you don't want it reducing and disrupting the flow of the gasses but that is in a race bike where you are chasing every 0.1hp
#143
Racer
Thread Starter
![Default](https://rennlist.com/forums/images/icons/icon1.gif)
1st March car was re-taxed and went to Redtek to have a couple of niggles looked at including swapping the oil tank for one I'd refurbed as the current one had cracked paint and the oil level seal was weeping which is a tank out job so it made sense to tie it all in with a service & get it sorted.
The oil leak was traced to two things: Firstly the RSR rocker seals I initially provided him to fit weren't much cop so oil was getting through and one of the lower magnesium rocker covers was kippered. I knew the rocker cover wasn't great when I first put it back together as it was heavily pitted from corrosion but couldn't find a spare set & didn't want to fork out for billet ones on top of the engine rebuild so powder coated it and crossed my fingers.
The rocker seals were replaced with a set of Nicks own which use an o-ring to seal and as luck would have it I actually had a single billet rocker cover which was the correct one so just stuck that on until I'm feeling brave/rich enough to buy a lower pair.
So the engine looks a bit of a patchwork quilt but suits the outside quite well.
It was so good to get it back, took a nice looong detour on the way back & it felt unbelievably quick after 3 months of VW TDI!
Refurbed tank:
![Name: P6210041_zps830e66c2.jpg
Views: 738
Size: 74.9 KB](https://rennlist.com/forums/attachments/964-forum/1205062d1501319695-964-engine-rebuild-p6210041_zps830e66c2.jpg)
RSR rocker seals:
![Name: IMGP3760Small_zps6f2cb1fa.jpg
Views: 788
Size: 104.6 KB](https://rennlist.com/forums/attachments/964-forum/1205063d1501319695-964-engine-rebuild-imgp3760small_zps6f2cb1fa.jpg)
Redtek rocker seals:
![Name: IMGP0257Small_zpsf2c0d379.jpg
Views: 742
Size: 115.7 KB](https://rennlist.com/forums/attachments/964-forum/1205064d1501319695-964-engine-rebuild-imgp0257small_zpsf2c0d379.jpg)
Engine mismatch!
![Name: P3050270Small_zps4919f977.jpg
Views: 734
Size: 90.7 KB](https://rennlist.com/forums/attachments/964-forum/1205065d1501319695-964-engine-rebuild-p3050270small_zps4919f977.jpg)
The oil leak was traced to two things: Firstly the RSR rocker seals I initially provided him to fit weren't much cop so oil was getting through and one of the lower magnesium rocker covers was kippered. I knew the rocker cover wasn't great when I first put it back together as it was heavily pitted from corrosion but couldn't find a spare set & didn't want to fork out for billet ones on top of the engine rebuild so powder coated it and crossed my fingers.
The rocker seals were replaced with a set of Nicks own which use an o-ring to seal and as luck would have it I actually had a single billet rocker cover which was the correct one so just stuck that on until I'm feeling brave/rich enough to buy a lower pair.
So the engine looks a bit of a patchwork quilt but suits the outside quite well.
It was so good to get it back, took a nice looong detour on the way back & it felt unbelievably quick after 3 months of VW TDI!
Refurbed tank:
![Name: P6210041_zps830e66c2.jpg
Views: 738
Size: 74.9 KB](https://rennlist.com/forums/attachments/964-forum/1205062d1501319695-964-engine-rebuild-p6210041_zps830e66c2.jpg)
RSR rocker seals:
![Name: IMGP3760Small_zps6f2cb1fa.jpg
Views: 788
Size: 104.6 KB](https://rennlist.com/forums/attachments/964-forum/1205063d1501319695-964-engine-rebuild-imgp3760small_zps6f2cb1fa.jpg)
Redtek rocker seals:
![Name: IMGP0257Small_zpsf2c0d379.jpg
Views: 742
Size: 115.7 KB](https://rennlist.com/forums/attachments/964-forum/1205064d1501319695-964-engine-rebuild-imgp0257small_zpsf2c0d379.jpg)
Engine mismatch!
![Name: P3050270Small_zps4919f977.jpg
Views: 734
Size: 90.7 KB](https://rennlist.com/forums/attachments/964-forum/1205065d1501319695-964-engine-rebuild-p3050270small_zps4919f977.jpg)
![Name: P3070275Small_zpse5a10af8.jpg
Views: 746
Size: 106.5 KB](https://rennlist.com/forums/attachments/964-forum/1205066d1501319695-964-engine-rebuild-p3070275small_zpse5a10af8.jpg)
#144
Racer
Thread Starter
![Default](https://rennlist.com/forums/images/icons/icon1.gif)
I'm thinking of taking a bit of a U-turn on the Corvette silencers. There is still quite a lot of work to do welding up the ends back on as they need a full bead all the way round the ends externally and around the end face which is all time and money (titanium welding rods are $$$).
The other reason is I recently bought a very nice silencer from a 997. The problem with this is that because I want heat I'm going to to stick with the 993 heat exchangers which exit facing towards each other and the 997 silencer is quite wide with the inlets and outlets on the end faces.
Because of this I may have to rob the 'X' pipe I made for the Corvette silencers to make an adaptor pipe a little bit like the Bischoff catalytic converter.
![Name: 993Bischoffcat99311321316_zps9fdf22c8.jpg
Views: 739
Size: 31.2 KB](https://rennlist.com/forums/attachments/964-forum/1205048d1501319518-964-engine-rebuild-993bischoffcat99311321316_zps9fdf22c8.jpg)
I've sketched up roughly what it will have to look like although I would really like to 'straighten out' some of it. The 993 flanges are at the water cutters so I've got a couple of weeks to figure it out but I also need to get prices for the 180 degree bends as I don't have enough pipe to make this. If they work out at silly money maybe the Corvette boxes and 'X' pipe can go on hold and I'll have to look out for some short headers to go directly into the sides of the silencer and weld a tin round hem for heat.
The other reason is I recently bought a very nice silencer from a 997. The problem with this is that because I want heat I'm going to to stick with the 993 heat exchangers which exit facing towards each other and the 997 silencer is quite wide with the inlets and outlets on the end faces.
Because of this I may have to rob the 'X' pipe I made for the Corvette silencers to make an adaptor pipe a little bit like the Bischoff catalytic converter.
![Name: 993Bischoffcat99311321316_zps9fdf22c8.jpg
Views: 739
Size: 31.2 KB](https://rennlist.com/forums/attachments/964-forum/1205048d1501319518-964-engine-rebuild-993bischoffcat99311321316_zps9fdf22c8.jpg)
I've sketched up roughly what it will have to look like although I would really like to 'straighten out' some of it. The 993 flanges are at the water cutters so I've got a couple of weeks to figure it out but I also need to get prices for the 180 degree bends as I don't have enough pipe to make this. If they work out at silly money maybe the Corvette boxes and 'X' pipe can go on hold and I'll have to look out for some short headers to go directly into the sides of the silencer and weld a tin round hem for heat.
![Name: GT2ExhaustAssembly_02_zps549e788c.jpg
Views: 749
Size: 28.9 KB](https://rennlist.com/forums/attachments/964-forum/1205049d1501319518-964-engine-rebuild-gt2exhaustassembly_02_zps549e788c.jpg)
#145
Racer
Thread Starter
![Default](https://rennlist.com/forums/images/icons/icon1.gif)
Slow progress but exhaust flanges are watercut and I've been hacking up the old Corvette exhaust so of half the exhaust is now tacked up.
![Name: P5230096Medium_zpsdc3ccc65.jpg
Views: 772
Size: 216.6 KB](https://rennlist.com/forums/attachments/964-forum/1204634d1501314783-964-engine-rebuild-p5230096medium_zpsdc3ccc65.jpg)
993 heat exchangers are at my welders ready to have the flanges flipped and I did a trial fit of the silencer. All seems to fit so far apart from it being a bit too wide so more bumper also needs to be hacked. Next step is to trial fit it onto an actual engine (instead of my wooden jig) and make a couple of 'J' pipes to link the silencer to the rest.
Hopefully have it done by Christmas.
![Name: P5230096Medium_zpsdc3ccc65.jpg
Views: 772
Size: 216.6 KB](https://rennlist.com/forums/attachments/964-forum/1204634d1501314783-964-engine-rebuild-p5230096medium_zpsdc3ccc65.jpg)
993 heat exchangers are at my welders ready to have the flanges flipped and I did a trial fit of the silencer. All seems to fit so far apart from it being a bit too wide so more bumper also needs to be hacked. Next step is to trial fit it onto an actual engine (instead of my wooden jig) and make a couple of 'J' pipes to link the silencer to the rest.
Hopefully have it done by Christmas.
![Name: P3160384Small_zps1a1d90e4.jpg
Views: 726
Size: 82.5 KB](https://rennlist.com/forums/attachments/964-forum/1204635d1501314783-964-engine-rebuild-p3160384small_zps1a1d90e4.jpg)
#146
![Default](https://rennlist.com/forums/images/icons/icon1.gif)
Thanks for the adventure! Starting my own soon and will use this thread as a guide...
#147
Racer
Thread Starter
![Default](https://rennlist.com/forums/images/icons/icon1.gif)
About time I updated this - Exhaust is now up and running. Took twice as long and cost twice as much as expected but it always does right?
I went away from the X pipe design as the LH & RH bank merge inside my silencer anyway + I think I really wanted to use the X because it took me a long time to make and had some very pretty welding on it. It was the only solution when I was going to use the Corvette silencers but maybe it will now make a pretty pen holder for my desk.
First was to finish my cheapie 993 heat exchangers so with the flanges cut off and jig made, they needed rotating,welding back on and linishing flat. The other side needed patching and a new pipe cobbled together. The steel on these is very thin and although stainless, it's not the best grade so can corrode.
![Name: P9040008Medium_zps0b74a306.jpg
Views: 741
Size: 199.3 KB](https://rennlist.com/forums/attachments/964-forum/1204231d1501310104-964-engine-rebuild-p9040008medium_zps0b74a306.jpg)
![Name: P9040026Medium_zpsa28c7b22.jpg
Views: 808
Size: 128.1 KB](https://rennlist.com/forums/attachments/964-forum/1204232d1501310104-964-engine-rebuild-p9040026medium_zpsa28c7b22.jpg)
![Name: P9040027Medium_zpsee7aed00.jpg
Views: 731
Size: 208.3 KB](https://rennlist.com/forums/attachments/964-forum/1204233d1501310104-964-engine-rebuild-p9040027medium_zpsee7aed00.jpg)
Old exhaust system removed:
![Name: P9040023Medium_zps37677322.jpg
Views: 754
Size: 269.4 KB](https://rennlist.com/forums/attachments/964-forum/1204234d1501310104-964-engine-rebuild-p9040023medium_zps37677322.jpg)
993 heat exchangers and new rear silencer fitted:
![Name: P9040029Medium_zps51801443.jpg
Views: 756
Size: 203.6 KB](https://rennlist.com/forums/attachments/964-forum/1204235d1501310104-964-engine-rebuild-p9040029medium_zps51801443.jpg)
Lots of expensive titanium pipework cut, bent, tacked and welded:
![Name: P9050043Medium_zps040eb798.jpg
Views: 757
Size: 148.4 KB](https://rennlist.com/forums/attachments/964-forum/1204236d1501310104-964-engine-rebuild-p9050043medium_zps040eb798.jpg)
Some lovely welds added:
![Name: P9050046Medium_zps75c38953.jpg
Views: 770
Size: 155.6 KB](https://rennlist.com/forums/attachments/964-forum/1204237d1501310104-964-engine-rebuild-p9050046medium_zps75c38953.jpg)
Lambda bosses welded on:
![Name: P9050051Medium_zps23400e21.jpg
Views: 764
Size: 152.5 KB](https://rennlist.com/forums/attachments/964-forum/1204238d1501310104-964-engine-rebuild-p9050051medium_zps23400e21.jpg)
Fitted
![Cool](https://rennlist.com/forums/images/smilies/cool.gif)
![Name: P9050056Medium_zps7f50b444.jpg
Views: 739
Size: 194.8 KB](https://rennlist.com/forums/attachments/964-forum/1204239d1501310104-964-engine-rebuild-p9050056medium_zps7f50b444.jpg)
There's always a few bits you think I could have done better and there's still some finishing to do as I may do double slip joints in two places and the tailpipes are just bits of tube at the moment but it's on and sounds good. It's still quite loud although much quieter than the Magnaflow but it now has a real rasp to it and makes a racket on overrun!
With the new exhaust I think the car is now running a bit richer but haven't done enough miles to really get to know it. I'll report back
![thumbsup](https://rennlist.com/forums/graemlins/bigok.gif)
The following users liked this post:
kos11-12 (03-07-2021)