vr6tee Posted November 13, 2015 Share Posted November 13, 2015 Well, it's winter again. That means it's time to take the car apart The car ran beautiful this year with over 1000 HP but I've decided it's time to do a full engine build. The stock internals can only take 1000 HP for so long. I'm aiming for 1300 Wheel Horse Power. Mods to achieve (1300 WHP) 1500+ crank HP: ----------------------------------------- 3.8L pistons (relieved for large valves) 3.8L iron ductile cylinder sleeves Carrillo Rods 3 layer stainless core head gaskets 5 axis CNC ported heads 5 mm oversized valves intake/exhaust 315/305 degree variable high lift camshafts 12 mm head studs SRM billet intake manifold dual throttle bodies SRM fuel rails full PTFE full system x-pipe intake with dual blow off valves 2 X 700 LPH brushless fuel pumps with controller Syvecs ECU SRM 4.5" intercoolers 2150 cc (205 lb) injectors custom v-band headers with 38 mm waste-gates 2 X Xona 7865 v-band turbos Switzer Exhaust with bypass valves Tilton triple clutch change from 20" to 18" wheels with MT ET streets Helical LSD DSS stage 5 axles E98 fuel The heads, cylinders and cams have been sent off for machining. Quote Link to comment
KMR 968 Turbo Posted November 13, 2015 Share Posted November 13, 2015 Wow! Where have you been all my life? LOL Welcome to the forums. I look forward to reading more about your build. Quote Link to comment
KevinJ Posted November 14, 2015 Share Posted November 14, 2015 I agree with Erik - welcome to the forum! This sounds like a pretty radical project for the winter. Feel free to document the journey with us, online or by submitting a story and photos for our newsletter. Good luck! Kevin Quote 22 Porsche Cayman GT4 21 BMW X5 Link to comment
Rick Posted November 14, 2015 Share Posted November 14, 2015 (edited) Welcome to the club vr6tee ... I don't believe we have met, but you certainly have caught our attention with your second post to the website. It's an intriguing and courageous project. As a life long DIY'er I will admit to never having undertaken an engine project as extensive as the one you have outlined above. Looking forward to your progress updates throughout the winter. Would enjoy seeing a picture/s of your car in a subsequent post. Again ... welcome Rick Barnes (aka Barnsey ) V.P. WRR PCA Edited November 14, 2015 by Rick Quote Link to comment
vr6tee Posted November 14, 2015 Author Share Posted November 14, 2015 Thanks for the welcome guys! I uploaded pics of the Switzer build I did this spring, it was a pretty big transformation and gave me the opportunity to learn a lot about the 997. I came from building high HP VW's. I guess I still am Here's a couple pics of the car: I should have the head, cams, pistons, sleeves, rods, cylinders back within the month. I'll take some pics of the engine assembly as it progresses. The goal is to have the car running by March and ready to dyno when the snow melts. Quote Link to comment
JT997TT Posted November 17, 2015 Share Posted November 17, 2015 HOLY. Yes, please share pics and progress. This will be a complete beast when completed. Thanks for posting Quote Jim 17 black/black Audi R8 V10 Plus - still within the VW family! a few minor upgrades 12 black/black Cayenne Turbo - a few minor cosmetic enhancements 91 black/black/black 911 C4 Cab - keeping it pretty OEM and basic Link to comment
vr6tee Posted November 17, 2015 Author Share Posted November 17, 2015 The pics from the previous build are located in my profile. Here's a link: http://www.porsche.ab.ca/album.php?albumid=59 Quote Link to comment
Brodie Posted November 17, 2015 Share Posted November 17, 2015 Awesome project! Did you buy an OEM Porsche cam timing tool or an aftermarket version? It seems like one of the biggest things people worry about is getting the cam alignment / timing perfect, wondering if you've tried it before? Quote Link to comment
vr6tee Posted November 17, 2015 Author Share Posted November 17, 2015 Awesome project! Did you buy an OEM Porsche cam timing tool or an aftermarket version? It seems like one of the biggest things people worry about is getting the cam alignment / timing perfect, wondering if you've tried it before? I'm "borrowing" an OEM cam tool. I bought a TDC indicator and have a degree wheel for setting TDC. I was looking at the Stomski GT3 cam timing tool which looks really nice but a buddy has the OEM cam tool so I might as well not waste the $1000 if I don't have to. Quote Link to comment
vr6tee Posted December 22, 2015 Author Share Posted December 22, 2015 3.8L pistons/liners, rods and 12 mm head studs are ready to install over the holidays..... Quote Link to comment
vr6tee Posted December 31, 2015 Author Share Posted December 31, 2015 10-12 mm head stud conversion. Quote Link to comment
malcolm Posted December 31, 2015 Share Posted December 31, 2015 nice conversion kit. are the new studs torqued into the block; double nut technique? loctite? Quote '21 Macan GTS PDK Miami Blue/Black, 7k kms '93 928 GTS 5 speed Polar Silver/Linen, 192k kms '88 928 S4 A/T Black/Ivory, 190k kms '09 Cayenne GTS Tiptronic Nordic Gold/Black, +336k kms '88 928 S4 A/T Red/Champagne, 110k miles (US car) Link to comment
vr6tee Posted December 31, 2015 Author Share Posted December 31, 2015 nice conversion kit. are the new studs torqued into the block; double nut technique? loctite? The new studs have a 6 mm hex head to install them Quote Link to comment
9Elfer Posted January 5, 2016 Share Posted January 5, 2016 Cripes, that is some serious horsepower. What levels of boost are you expecting to run? Marc Quote Link to comment
vr6tee Posted January 6, 2016 Author Share Posted January 6, 2016 Cripes, that is some serious horsepower. What levels of boost are you expecting to run? Marc I have 5 different boost maps switch-able via my cruise stalk ranging from 17-35 psi. My cams are scheduled to arrive back from Germany today.... I'm expecting all of my engine components/gaskets/bearings to arrive back by next weekend. After that, the engine assembly will resume..... Quote Link to comment
vr6tee Posted March 2, 2016 Author Share Posted March 2, 2016 I "finally" received all my engine parts back last week. Here are some updated pics. The long block is officially complete. Now I am waiting for receive my new clutch and turbo components. I'm hoping they arrive in the next 2 weeks so I can get them installed and then engine/trans back in the car. Quote Link to comment
vr6tee Posted March 4, 2016 Author Share Posted March 4, 2016 Almost Complete... (Images are always upside down no matter which way I turn them) Quote Link to comment
dragon Posted March 4, 2016 Share Posted March 4, 2016 Amazing! Can't wait to see this one on a drive! (or sit shotgun!) Quote Link to comment
vr6tee Posted March 6, 2016 Author Share Posted March 6, 2016 Engine is ready to go in, just waiting for more parts.... Quote Link to comment
JT997TT Posted March 6, 2016 Share Posted March 6, 2016 Hats off man. That's a crazy undertaking and I love seeing your pics. Also can't wait to hear and see your car in person. Quote Jim 17 black/black Audi R8 V10 Plus - still within the VW family! a few minor upgrades 12 black/black Cayenne Turbo - a few minor cosmetic enhancements 91 black/black/black 911 C4 Cab - keeping it pretty OEM and basic Link to comment
vr6tee Posted March 6, 2016 Author Share Posted March 6, 2016 Full billet shifter and cables... Quote Link to comment
dragon Posted March 6, 2016 Share Posted March 6, 2016 Numeric Racing, very nice! Quote Link to comment
vr6tee Posted March 10, 2016 Author Share Posted March 10, 2016 Ported vs stock intake Quote Link to comment
vr6tee Posted March 11, 2016 Author Share Posted March 11, 2016 New mill. I machined the turbo oil tanks Vacuum lines parts assembled Quote Link to comment
vr6tee Posted March 17, 2016 Author Share Posted March 17, 2016 Plenum getting machined. Quote Link to comment
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