BBi Autosport Mahle Motorsports 964 3.6L TO 3.8L Engine Build Thread
#16
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BBI built the Zwart Pike's Peak cars... I walked through there shop last November while in Huntington on a work trip. I was very impressed. Jeff's car was out back, and I got to poke around in it as well. It was a world class motorsport spec build. It's hard to hide bad quality if you let people stick their head in for a surprise visit!
I know a few of their guys have PMNA experience, and it really showed through in the cars that I saw. It was OEM level of detail.
I know a few of their guys have PMNA experience, and it really showed through in the cars that I saw. It was OEM level of detail.
Thank you for the kind words! We just moved to a bigger facility earlier this year, and our shop is always open for a shop tour to all Rennlist members. Just shoot us an email to sales@bbiautosport.com to give us a heads up!
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Yes, racing traditions run deep here at BBi Autosport. Betim, the company's founder & technical director,has worked in Racing for many years at prestigious events like the 24 Hours of Lemans and 24 Hours of Daytona. First for Fordhal Motorsport working on their GT3RS and Saleen S7 in ALMS and Grand Am series, Alex Job Racing on their ALMS GT3RSR, J3 Racing working on their GT3RSR and then Porsche Motorsports North America as their dyno tech an supporting Porsche teams at ALMS, Grand Am, Speed World Challenge events. Sharing the same passions, most of BBi's support and shop staff have also previously worked for other motorsport programs as well.
- Jerry@BBiAutosport.com
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Bringing Passion, Artistry, Craft to the Porsche Tuning Industry
Southern California's Porsche Performance Tuning, Engine Development,
ECU Software Tuning, Custom Fabrication, Race Preparation & Factory Service Center
Website: www.bbiautosport.com Email: sales@bbiautosport.com Phone: (714) 843-0200
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Bringing Passion, Artistry, Craft to the Porsche Tuning Industry
Southern California's Porsche Performance Tuning, Engine Development,
ECU Software Tuning, Custom Fabrication, Race Preparation & Factory Service Center
Website: www.bbiautosport.com Email: sales@bbiautosport.com Phone: (714) 843-0200
Follow Us On: Facebook & Instagram
#17
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Great looking engine and nice photography skills.
I'm really interested in this as I've asked the question a few times and the last time I asked a reputable source I was told that 'the slip-in cylinders go out of round within 10K miles, regardless how the car is used and its reflected in the leakdown values. One finds uncontrolled blowby and there is really nothing one can do beyond replacement'.
I asked my engine builder and he said I read too much 'stuff' on the the internet so there is certainly difference of opinion out there.
I can understand the thinking behind the smaller wall thickness causing ovality in the cylinders but at the same time it's something I would love to do but not if it will cause me tears further down the road!!
Can I ask if you have an opinion on this and why you didn't just machine the case seeing as it was all apart anyway?
Thanks
I'm really interested in this as I've asked the question a few times and the last time I asked a reputable source I was told that 'the slip-in cylinders go out of round within 10K miles, regardless how the car is used and its reflected in the leakdown values. One finds uncontrolled blowby and there is really nothing one can do beyond replacement'.
I asked my engine builder and he said I read too much 'stuff' on the the internet so there is certainly difference of opinion out there.
I can understand the thinking behind the smaller wall thickness causing ovality in the cylinders but at the same time it's something I would love to do but not if it will cause me tears further down the road!!
Can I ask if you have an opinion on this and why you didn't just machine the case seeing as it was all apart anyway?
Thanks
Thanks for the kind words! We are glad that you appreciate the little details!
![rockon](https://rennlist.com/forums/graemlins/rockon.gif)
Mahle Motorsports are one of the top leaders in the industry and we've had great experiences with this particular kit. Our clients have logged on many track miles without any issues.
In comparison, the machine fit cylinders would be stronger but it would require machine work and cost more. Machine fit is better suited for turbocharged applications so the slip in would suffice for this build.
- Jerry@BBiAutosport.com
#18
Race Car
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thanks for all the detail Jerry and the awesome photos which in themselves are superb.
How you like dem apple Quad?![Wink](https://rennlist.com/forums/images/smilies/wink.gif)
Jerry what cams and engine/fuel management are planned? Looking forward to the follow-ups.
How you like dem apple Quad?
![Wink](https://rennlist.com/forums/images/smilies/wink.gif)
Jerry what cams and engine/fuel management are planned? Looking forward to the follow-ups.
#19
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Very nice build indeed! Have you thought about boat tailing and shuffle pinning the crank cases? I don't think there are any material HP gains but the boat tailing method should, in theory, provide additional torque related improvements.
Cheers, Mark
Cheers, Mark
#20
Race Director
#21
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We understand that air-strip or drag racing might not be interesting to everyone as some might dismiss it as just a short display of brute power.
Project King Kong has long been a testbed for our engine developement program as it requires us to push it to extreme conditions and make as much reliable power as possible.
All of the data and knowledge that we have acquired from the Project King Kong have been passed on to other sucessful motorsport programs such as our championship winning Pikes Peak Porsche 997 GT3 Turbo Cup. Sharing the same BBi Built 3.8 liter engine shortblock as King Kong, our 997 GT3 Turbo Cup took the Time Attack 1 class win earlier this year with a time of 9:46.243.
For those who might be unfamiliar with the Pikes Peak International Hill Club (PPIHC), it is an annual automobile and motorcycle hill climb to the summit of Pikes Peak in Colorado, USA. The grueling course measures 12.24 miles over 156 turns, climbing 4,720 ft from the start at Mile 7 to the finish at 14,114, on grades averaging 7%.
BBi Porsche 997 GT3 TurboCup w/ Built 3.8 Engine
2015 Pikes Peak International Hill Club Time Attack 1 Class Winner
Jeff Zwart- Pikes Peak International Hill Climb 2015
In Car Footage:
![](https://c1.staticflickr.com/1/575/21805471141_9b5cc67088_h.jpg)
![](https://c1.staticflickr.com/9/8829/18436491655_cb6ef0ac00_h.jpg)
![](https://c2.staticflickr.com/8/7751/18248669938_5b3aeb059e_h.jpg)
![](https://c1.staticflickr.com/9/8896/17813852294_6eadd336cf_h.jpg)
![](https://c1.staticflickr.com/9/8848/17815748173_6158a368a7_h.jpg)
![](https://c1.staticflickr.com/1/461/18248603248_7d7a9e4a93_h.jpg)
![](https://c1.staticflickr.com/9/8756/18439214051_e14b5ccadc_h.jpg)
![](https://c1.staticflickr.com/9/8828/17816798403_83fd96a637_h.jpg)
- Jerry@BBiAutosport.com
Project King Kong has long been a testbed for our engine developement program as it requires us to push it to extreme conditions and make as much reliable power as possible.
All of the data and knowledge that we have acquired from the Project King Kong have been passed on to other sucessful motorsport programs such as our championship winning Pikes Peak Porsche 997 GT3 Turbo Cup. Sharing the same BBi Built 3.8 liter engine shortblock as King Kong, our 997 GT3 Turbo Cup took the Time Attack 1 class win earlier this year with a time of 9:46.243.
For those who might be unfamiliar with the Pikes Peak International Hill Club (PPIHC), it is an annual automobile and motorcycle hill climb to the summit of Pikes Peak in Colorado, USA. The grueling course measures 12.24 miles over 156 turns, climbing 4,720 ft from the start at Mile 7 to the finish at 14,114, on grades averaging 7%.
BBi Porsche 997 GT3 TurboCup w/ Built 3.8 Engine
2015 Pikes Peak International Hill Club Time Attack 1 Class Winner
Jeff Zwart- Pikes Peak International Hill Climb 2015
In Car Footage:
![](https://c1.staticflickr.com/1/575/21805471141_9b5cc67088_h.jpg)
![](https://c1.staticflickr.com/9/8829/18436491655_cb6ef0ac00_h.jpg)
![](https://c2.staticflickr.com/8/7751/18248669938_5b3aeb059e_h.jpg)
![](https://c1.staticflickr.com/9/8896/17813852294_6eadd336cf_h.jpg)
![](https://c1.staticflickr.com/9/8848/17815748173_6158a368a7_h.jpg)
![](https://c1.staticflickr.com/1/461/18248603248_7d7a9e4a93_h.jpg)
![](https://c1.staticflickr.com/9/8756/18439214051_e14b5ccadc_h.jpg)
![](https://c1.staticflickr.com/9/8828/17816798403_83fd96a637_h.jpg)
- Jerry@BBiAutosport.com
#22
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I'm sure you guys build a fine motor. But the pikes peak car, which I'm guessing makes less than 800bhp at sea level, is more impressive.
How often do you rebuild it?
How often do you rebuild it?
#23
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Yes, it is tuned to make approximately make that much power and it has ran 3 seasons without a rebuilt.
#24
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Nice looking build though
#27
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Full disclosure: I've used BBI as my exclusive shop on my dedicated GT3RS track car & my 89 carrera for nearly 3 years (hell they did work on my cayenne recently too). Very happy customer. And I'm an **** ***** when it comes to working on my cars, they do good work with an eye to detail you will not see in most shops.
Last edited by Spyerx; 09-29-2015 at 01:25 PM.
#28
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I've seen the inside of a number of world championship winning race shops and from what I can see BBi have a very presentable set. They should be proud of their race achievements and I'm glad they are taking the time to show us a little of what they can do.
Looks to me a bit more than just another tuner shop
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#29
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Thanks for the kind words and support!
![Cheers](https://rennlist.com/forums/images/smilies/beerchug.gif)
Everything else including the cams will be stock.
![](https://c2.staticflickr.com/6/5697/21046735851_f34a287ae0_h.jpg)
![](https://c1.staticflickr.com/1/691/20418060773_1bd781ea5a_h.jpg)
![](https://c1.staticflickr.com/1/694/21012888436_2cf3421076_h.jpg)
![](https://c2.staticflickr.com/6/5782/20852317339_dd96f4d890_h.jpg)
![](https://c2.staticflickr.com/6/5710/20852318379_4e4fce682e_h.jpg)
- Jerry@BBiAutosport.com