I've just returned from a few weeks away and what do I find? Some extremely well packed boxes from Greg & Mary Lou Brown.
I openned them very carefully to find a 95.25mm stroke crank, 8 968 104m pistons, nicely modded for my 86 motor. Rings, pins, big ends, mains and 2 nicely modded 968 head gaskets.
The most impressive of all has to be the Carillo con rods. Almost too pretty to hide in the motor.
If that wan't enough, there was also a sump spacer kit complete with a nice big syringe of Mercedes gasketless sealant.
I must hank Greg & Mary Lou very much, as this wouldn't have happened without their time, skill and kindness.
Some pics of my shed, body, dirty bits, Aqua Blasted bits.

 

They're great people to deal with! Keep us posted on your progress, with lots of pics. Workshop looks great and the rotisserie ... way to go

 

Those hydroblasted components look very impressive.

I hope you will document your engine build with pics as and when it progresses.

Wishing you every success with the build.

Rgds

Fred

 

have P.M.ed you please contact, very interested. Cheers Roy

 

We need pics of the stroker parts!
Wow! Those are precious parts (expensive) to be shipped all the way to Australia.

We need pics.
Hoi

 

Post pics of the engine parts, not the chassis!

 

I'd like to learn more about the water blast.

 

^ me too. Is this the same process as vapor blasting which uses water to carry the abrasive media in a slurry?

 

It's a bit like taking a shower but at 40,000 psi -

 

Thanks guys.
I want to take pics of the parts also but they are boxed and so safe [except the crank], I'm a bit nervous about handling them. I will though.
I don't know much about the cleaning process because a mate took it there for me and returned it as is. but here's what they say.

"Wet Bead Blasting in Adelaide, Vaqua Blasting, Hydra Blasting, Water Blasting, Vapour Blasting, Aqua Blasting
Simply the best "non aggressive"
•Non damaging finish
•Non abrasive finish
•Non toxic or harmfull cems used
•Coats components with rust inhibitor
•Up to size of Alloy engine block or 4WD rim with tyre
•This process works for steel, brass, copper, plastic and wood
For pick up and delivery in Adelaide."

I bought the rotissery for this job and plan to sell it after.
I'm definitely at the stage where this is my last project and it will be very slow because I am and I'm funding it in my retirement.

I've always dreamed of a ground up 928 rebuild and then I read Carl's [flyvmo] very impressive project and he inspired me to give it a go.

It's pictured in my signature as I bought it after sitting in the open for 2 years. It looked disgusting when it arived, with multiple rats nests under the bonnet. They had even gone up the intake pipes and eaten all the paper off the element!
It's a testament to Porsche's build quality because it has suffered very little from this mal treatment and only having travelled 117k kms it's in very good condition underneath.

It's my 6th 928 and the rebuild will be non standard for sure but still look pretty much as a 1986 S model with a GTS spoiler and 18" Carrera III rims.
The 6.5 litres will be fed by 2 Bosche electronic throttle bodies, through an S4 inlet manifold.
It will be ignited by 8 Cayenne Coil on plug modules and the whole thing managed by a Link G4+ Thunder EMS.
The Link Thunder gives me 2 ETB, any electronic pedal, 2 WBO2 sensors, 2 knock sensors and will happily control the Cayenne COPs.
I've bought an InfinityBox wiring system which is being programmed as we speak.
This will be the 5th 928 engine build for me but the first non standard one. Although I did convert a 4.5L to a 4.7L S .We are lucky to have a very competant alloy block engine machine shop here who I've used before to rebore a 928 block. It will be a while before this block gets there to become a 104mm bore because of cost and time. The engine is on the stand and still complete.
Enough for now.

 

A couple of pics.
The Cayenne COPs fit the 928 perfectly, they just needed a mounting point.

 

I've just removed the intank fuel pump and it's a disaster. Wires broken and rubber hose broken.
As these intank pumps were not used by Porsche in losts of places, what is the considered view on their impotance?
I have a Bosch 044 pump to fit to this rebuild, so is that alone enough to feed the 6.5 litres?
I'm using new fuel rails and EMS.

 

Carillo rods are the business. That car will be a beast!

 

Cool project !!

There's been lots written here about the in-tank pumps, and opinions are divided. Certainly in terms of volume the 044 does not need any help (nor does the stock pump with a stock motor). The issue is heat, fuel vapor pressure and suction, and all will vary. Fuel vaporizes at high temps and low pressures (e.g. at the pump inlet), and fuel pumps can't pump vapor. The in-tank pump adds a little pressure at the main pump inlet and avoids the problem.

It is not a common problem, and Porsche themselves have gone back and forth: The 924 used the same in-tank pump, 944s did not, early 928s had them but most of the '80's did not, then in '90 or so they went back to them. Our '88 did not have an in-tank pump, after spending all afternoon in the baking sun waiting for a tow truck it now does. Our GT had the in-tank from the factory and still does, feeding an 044. Works fine.

Porsche never used in-tank pumps on 911s, but remember that the fuel tank is in the front, I think that makes a big difference. And since 2000 or so, pretty much everything has gone to in-tank pumps.

The 928 in-tank pump has gotten absurdly expensive but if you have one then I would use it. Replace the little hose with something that is ethanol-resistant, repair the wires and you should be all set. The little turbine pump itself seems to last a very long time, it is the stupid little hose that causes trouble.

 

Thanks Jim.
I have a spare S/H intank pump, so I'll work on that and use the combination.
It gets seriously hot here in summer, mid 40C.