Black Betty - Part 3 Engine rebuild
07-03-2012, 10:10 AM
#1
Drifting
Thread Starter
Black Betty - Part 3 Engine rebuild
Hi,
After a lot of research and generous advice from specialist & rennlisters my rebuild has finally begun. Special thanks to Colin, Geofferey, Peter, Spencer, Alex, Grant, Steve and all the kind words of encouragement/ advice from everyone who posted in my previous threads.
The purpose of this thread will be to, talk specifics - I will list components used and reasons to the best of my ability. Experience - I will cover my choice of builder and the people I've crossed along the way. In hopes to help them gain exposure through my experience.
I won't however be talking about the cost - every build is different and money is something that I don't tend to talk about.
I hope this thread will be useful, interesting and above all help those that do read it.
The builder - RedTek, Nick Fulljames
After a lot of thought, quotes, kind and generous advice from other specialists I chose to go with Nick.
Nick has been working in engine development for the past 25 years. Which has included F1 Maclaren and touring car. He's a specialist 911 race engine builder and supplies turn key engines for Porsches from 1967 to 1997 for track, road and Hillclimbing. Indeed he's also rebuilt rare Le Mans Porsche engines...
He only builds engines - that is all he does every day of the week. Nick who is RedTek is the builder of every engine that leaves his workshop. He is fully equipped with a machining room - everything to do with building is in house. All this to say when you go with RedTek - you know who the builder is.
He's infectious about engines and perspires passion for what he does. He places the strongest perfectionism on the builds he takes on because he sees them as his very own, a testament to himself and what he is about. Because at the end of the day the RedTek name is his name. He is the builder.
Even though he has about 8 engines going at one given time ranging from 2.0 ltr stock builds to 3.5 ltr screamers to 3.8 ltr monsters he's given me attention as if I were his only and first customer.
Engine - 3.8 throttle boddies
After long conversations that I had to end where we covered exactly how I'd be using the car and what I was looking to achieve we came up with the spec.
The principal being that the engine will be powerful with low end grunt but must last another 20 years.
Here is the spec we came up with...
Full blue print, balanced rebuild. Boat tail engine case.
Barrels & Pistons:
We decided to go with 3.8 Mahle barrels and pistons. For reliability nothing seems to be more so - after all it's what Porsche used. Whilst other combinations may be better suited for performance gains on track the compromise is a shorter life. So we went with Mahle. 3.8 to give higher torque figures. Including new rings, pins and clips.
Throttle bodies:
We're going with PMO throttle bodies as these are the ones Nick has most experience with. Whilst they may not be as finely tuneable and slightly more expensive than Jenvey items it is what he feels most comfortable with and he's got the best results with. Throttle bodies as this will allow for better breather and higher revs - as a bonus the induction noise will be phenomenal.
Engine management:
After long conversations with several tuners and providers we've settled on the latest gen Motec M84. Other options were looked at however again this is the system Nick has had the best results with and as a bonus he has several base maps to work from. The subsequent rolling road remap will take place but the mapper has tbc. Exploring several options.
Exhaust:
For the best results we will be using a local race exhaust manufacturer that nick has used extensively. He is cheaper than Hayward & Scott, BB exhaust, Fabspeed and Nick has experienced better results with him - this will include headers, a silencer and twin outlet.
Valves:
We will be using new similar to original spec valves with the view that the results he has seen have been negligible on the basis of using original cylinder heads as the exhaust ports are ceramic coated and cannot easily be opened up without additional cost. Titanium retainers & heavy duty valve springs will be used to help keep the engine robust at the higher RPM. New guides.
Cams:
We will be using RSR cams as these are high lift and suited to ITBS. Had we gone with forced induction in the form of a supercharger (out of budget) we would have used Cup cams.
Cylinder heads:
It would have been great to use different heads as Nick estimates a 15hp increase alone however we have decided against these as they are beyond budget. It may be one for the future.
Connecting Rods:
Our choice was between Pauter or Carrillo forged rods. In the end both are good so it was down to price - Pauter. These have been chosen as the rev limit will be higher.
Head studs & through bolts:
With the aforementioned we have decided on ARP headstuds & through/ case bolts as they to will beef up the engine to deal with the added performance.
Chains & Guides:
At this point in the engines life it is common place to replace these. New chains, ramps and tensioners.
Cam spray tubes:
I believe we are keeping the original items and cleaning them out.
Rockers:
Shot peened.
Crank assembly:
Balanced, polished and tolerances checked.
Gaskets:
All new.
Big end bolts:
ARP for reliability with the aforementioned power increase.
All new bearings.
Rocker shaft seals:
RSR items for a better seal.
Oil pump:
We decided to keep a standard oil pump based on Nick's experience.
Update 1
* Thus far the engine has been dropped and completely stripped.
* The crank has been checked for tolerances and passed, big sigh of relief. Next will be to balance and polish.
* The heads have been vapour blasted and degreased.
* Nick tells me there's evidence that the bottom end has been apart at some point as the crank pin for the nose bearing was missing.... ! I have paper work for a top end by a previous owner that was badly done by a non Porsche specialist but nothing re the bottom end...
* Waiting on the new barrels, pistons and ARP parts from the US that should be arriving by the end of the week.
* Old P&Cs were not in too bad a state - will sell those on along with other parts not going back on car.
* We've decided to keep the air conditioning unit.
* LWFlywheel and RS Clutch will checked for tolerances.
* Fan shroud, covers will all be guards red with the fan black.
* We would have expected just below 400HP had we gone with uprated cylinder heads, rockers, more aggressive cams - out of budget and drivability.
Apologies if some of the aforementioned may not make sense - I'm no pro. I'm sure I've missed out many details but this is what I can remember off the top of my head. As always your collective feedback and encouragements are much appreciated.
Cheers to this forum and the help
Here are some photos thus far...
After a lot of research and generous advice from specialist & rennlisters my rebuild has finally begun. Special thanks to Colin, Geofferey, Peter, Spencer, Alex, Grant, Steve and all the kind words of encouragement/ advice from everyone who posted in my previous threads.
The purpose of this thread will be to, talk specifics - I will list components used and reasons to the best of my ability. Experience - I will cover my choice of builder and the people I've crossed along the way. In hopes to help them gain exposure through my experience.
I won't however be talking about the cost - every build is different and money is something that I don't tend to talk about.
I hope this thread will be useful, interesting and above all help those that do read it.
The builder - RedTek, Nick Fulljames
After a lot of thought, quotes, kind and generous advice from other specialists I chose to go with Nick.
Nick has been working in engine development for the past 25 years. Which has included F1 Maclaren and touring car. He's a specialist 911 race engine builder and supplies turn key engines for Porsches from 1967 to 1997 for track, road and Hillclimbing. Indeed he's also rebuilt rare Le Mans Porsche engines...
He only builds engines - that is all he does every day of the week. Nick who is RedTek is the builder of every engine that leaves his workshop. He is fully equipped with a machining room - everything to do with building is in house. All this to say when you go with RedTek - you know who the builder is.
He's infectious about engines and perspires passion for what he does. He places the strongest perfectionism on the builds he takes on because he sees them as his very own, a testament to himself and what he is about. Because at the end of the day the RedTek name is his name. He is the builder.
Even though he has about 8 engines going at one given time ranging from 2.0 ltr stock builds to 3.5 ltr screamers to 3.8 ltr monsters he's given me attention as if I were his only and first customer.
Engine - 3.8 throttle boddies
After long conversations that I had to end where we covered exactly how I'd be using the car and what I was looking to achieve we came up with the spec.
The principal being that the engine will be powerful with low end grunt but must last another 20 years.
Here is the spec we came up with...
Full blue print, balanced rebuild. Boat tail engine case.
Barrels & Pistons:
We decided to go with 3.8 Mahle barrels and pistons. For reliability nothing seems to be more so - after all it's what Porsche used. Whilst other combinations may be better suited for performance gains on track the compromise is a shorter life. So we went with Mahle. 3.8 to give higher torque figures. Including new rings, pins and clips.
Throttle bodies:
We're going with PMO throttle bodies as these are the ones Nick has most experience with. Whilst they may not be as finely tuneable and slightly more expensive than Jenvey items it is what he feels most comfortable with and he's got the best results with. Throttle bodies as this will allow for better breather and higher revs - as a bonus the induction noise will be phenomenal.
Engine management:
After long conversations with several tuners and providers we've settled on the latest gen Motec M84. Other options were looked at however again this is the system Nick has had the best results with and as a bonus he has several base maps to work from. The subsequent rolling road remap will take place but the mapper has tbc. Exploring several options.
Exhaust:
For the best results we will be using a local race exhaust manufacturer that nick has used extensively. He is cheaper than Hayward & Scott, BB exhaust, Fabspeed and Nick has experienced better results with him - this will include headers, a silencer and twin outlet.
Valves:
We will be using new similar to original spec valves with the view that the results he has seen have been negligible on the basis of using original cylinder heads as the exhaust ports are ceramic coated and cannot easily be opened up without additional cost. Titanium retainers & heavy duty valve springs will be used to help keep the engine robust at the higher RPM. New guides.
Cams:
We will be using RSR cams as these are high lift and suited to ITBS. Had we gone with forced induction in the form of a supercharger (out of budget) we would have used Cup cams.
Cylinder heads:
It would have been great to use different heads as Nick estimates a 15hp increase alone however we have decided against these as they are beyond budget. It may be one for the future.
Connecting Rods:
Our choice was between Pauter or Carrillo forged rods. In the end both are good so it was down to price - Pauter. These have been chosen as the rev limit will be higher.
Head studs & through bolts:
With the aforementioned we have decided on ARP headstuds & through/ case bolts as they to will beef up the engine to deal with the added performance.
Chains & Guides:
At this point in the engines life it is common place to replace these. New chains, ramps and tensioners.
Cam spray tubes:
I believe we are keeping the original items and cleaning them out.
Rockers:
Shot peened.
Crank assembly:
Balanced, polished and tolerances checked.
Gaskets:
All new.
Big end bolts:
ARP for reliability with the aforementioned power increase.
All new bearings.
Rocker shaft seals:
RSR items for a better seal.
Oil pump:
We decided to keep a standard oil pump based on Nick's experience.
Update 1
* Thus far the engine has been dropped and completely stripped.
* The crank has been checked for tolerances and passed, big sigh of relief. Next will be to balance and polish.
* The heads have been vapour blasted and degreased.
* Nick tells me there's evidence that the bottom end has been apart at some point as the crank pin for the nose bearing was missing.... ! I have paper work for a top end by a previous owner that was badly done by a non Porsche specialist but nothing re the bottom end...
* Waiting on the new barrels, pistons and ARP parts from the US that should be arriving by the end of the week.
* Old P&Cs were not in too bad a state - will sell those on along with other parts not going back on car.
* We've decided to keep the air conditioning unit.
* LWFlywheel and RS Clutch will checked for tolerances.
* Fan shroud, covers will all be guards red with the fan black.
* We would have expected just below 400HP had we gone with uprated cylinder heads, rockers, more aggressive cams - out of budget and drivability.
Apologies if some of the aforementioned may not make sense - I'm no pro. I'm sure I've missed out many details but this is what I can remember off the top of my head. As always your collective feedback and encouragements are much appreciated.
Cheers to this forum and the help
Here are some photos thus far...
Last edited by Porsche964FP; 08-01-2012 at 07:25 PM.
.......sounds like the ultimate BHP and sound........is going to be epic.
07-03-2012, 11:13 AM
#6
Drifting
Thread Starter
Cheers SML
Like an operating theatre - but he apologised for the mess, apparently it's usually tidier.
The exhaust will have small heat exchangers, I'll keep blankets in the boot.
The exhaust will have small heat exchangers, I'll keep blankets in the boot.
07-03-2012, 11:47 AM
#7
Nordschleife Master
Trending Topics
07-03-2012, 11:53 AM
#8
Burning Brakes
Awesome! I appreciate how much thought and planning you are putting into this project, with a clear goal in sight. You obviously are someone who, when they decide to do something, does it right!
Looking forward to seeing and hearing about the progress.
Best of luck.
Looking forward to seeing and hearing about the progress.
Best of luck.
07-03-2012, 02:08 PM
#11
Rennlist Member
