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Re: UK Outlaw

Posted: Mon Jan 08, 2024 5:06 pm
by Graham Kerr
Hey Karl, yes I've seen these filters but I'm so restricted on height especially where the back two chokes sit and the engine lid comes down on them. I have a pal who runs the Jenvey injection set up, although it is on a 911, he has individual filters that just snap individually on the top of the ram pipes. I reckon the actual filtration isn't that good but it's got to be better than F all.

Re: UK Outlaw

Posted: Mon Jan 15, 2024 2:12 pm
by Karl Hashmi
Graham, if you don't find another solution you could speak to ITG, as I know they do custom fits also.
They may be able to provide exactly what you need?
Could be worth a chat with them.
Karl

Re: UK Outlaw

Posted: Sun Feb 25, 2024 2:36 pm
by Graham Kerr
So tomorrow I shall be driving down to Piddlehinton to pick up my engine case. Yes, a lovely name for a little village down in deepest Dorset. Here resides my machine man and the reason he has the case again is that when we installed the crank we felt the tiniest resistance which was barely 5 degrees out of 360 but this was not perfect so the motor had to be torn down for a couple of light passes with the line bore weapon. There was something else we found and this was the bottom skirt of the piston hitting the lower part of the engine case. This does sound diabolicaly serious but it was just a simple error between me and the machine man. Whilst I gave him the piston and barrel which was 92 mil for a 2.8 litre engine, he had set up the depth for the boring bar for the usual 90 mil 2.7 engines. But the 92 has just a tad more stroke so a few more thou clearance was required. When I was speaking with the Mahle rep in Germany he did mention that the 92 piston being a RS item was a lot different to the run of the mill 90 and I simply forgot to pass this info to Stuart the machinist. This is no problem apart from putting the engine build back a couple of weeks.
With some 356 downtime on my hands I thouight I should try something that had been in the back of my mind for sometime. It's just a handling problem I thought I may be able to resolve. When I'm giving the Wee Beastie some serious beans into a corner, that means I'm overdriving the car, the front of the car picks up almost as if it's starting to oversteer. Because the rear of the car is fairly stiff with Koni coil overs and no torsion bars, the front feels very loose. One day when I've got a bunch of spare cash and time I shall chop out all the stock front suspension and fit in either a 911 set up or a four bar arrangement both, joyfully with rack and pinion steering but for now I thought a first step could be to stiffen the anti roll bar, I think you call it a sway bar. The stock size is 15mil but you can buy a 16 and a 17.5 'sport'. Only problem, they are the best part of 500 pounds which seems, like a load of Porsche stuff, excessive. So I reckon I should knock a bar up myself and keep the costs down. What I did was something that I had quite a few years ago on my clubsport 1650 Lotus 105E Anglia and this was an additional bar hung off the existing one. As I said, deadly cheap and quite quick to make. I used a length of 10mil bar and block of alluminium. I chopped the alloy into four on my bandsaw then drilled the bars slightly undersize so they would clamp well. Then sliced the 4 alloy blocks, I had to hacksaw these as they were too small for the band saw, then drilled and tapped them 8mil, heated and bent the bar, bit of paint and job done.
Obviously, I can't tell you if this works or not, well not yet anyway, but I can easily go for a larger size bar if I feel I am going in the right direction to cure my handling woes.

Re: UK Outlaw

Posted: Wed Apr 03, 2024 8:51 am
by Graham Kerr
Got the cases back and the guys did a perfect job with the additional machining requirements that were needed. The bottom end is all bolted up but now there is further problem with the estimated compression ratio. We can't move the barrels up by using a larger base gasket, not that we want to because the 92mil barrels are not O ringed, as this tightens up the cam chains and they are on max as it is. The heads are finished and cc'd to .01 of a cc so I really don't want to start mucking around with them. The final figure for them is 63.7cc but the pistons are designed for a head volume of 68cc. As it stands this gives a comp ratio of approx 11.3 to 1 so I don't think I shall be strapping the twin turbos on just yet. Jokes over, what we are doing now is fly cutting the valve reliefs on the pistons. We shall cc the tops after this has been completed, and the amount that will be shaved will be something of a guess-timation because you are not dealing with a full circle just a half round on the top of the piston. With the cc figure we shall calculate how much we can shave off the top of the piston to effectively give us a comp ratio of approx 101/2 to 1. When this lot has been done and when it goes on the dyno, I hope there will be no pre ignition. I have only got a stock T distributor but I might get a better curve with a S dibby, we shall see.
And O.M.G. there is only one month to go before Portugal. I'm trying not to panic, the rest of the car is sorted, I've even got hold of a suit carrier for my DJ. I did get one tip which I'm sure is very useful. Follolwing a full gearbox rebuild, which my 915 has been, in order to fully lubricate all nooks and crannies, bearings and gears and anything else lurking within the gearbox internals, you should upend the box, best do this with a hoist, turn it all sides, up down, left, right so on the first drive every part has a good layer of EP. Bit basic but sort of makes sense, eh.

Re: UK Outlaw

Posted: Sat Apr 20, 2024 2:32 pm
by Graham Kerr
Apologies for getting a bit technical but it's all I've got left now. Anyway the engine finally is complete, everything is bolted down and I'm ready to rock. Unfortunately there is a television film crew arriving at the dyno shop on Monday to ponse around and film 911 stuff for an upcoming production. I have knowledge of these TV associated people and they are all dicks, they f**k around and do nothing, waste time, nothing is ever right for them, too much shade, too much light plus they are generally just 'lovely' if you know what I mean. However, this bunch of fairies are effectively delaying me getting my engine on the dyno and getting it tuned and sorted. I shall be banging on the door Thursday morning that's the 25th April and cranking it up to 73 thou and hopefully seeing something North of 250 brake. Although the engine internals are good for 8K and maybe a bit more, I have only a standard distributor although it is built to S specs it's not the best piece of kit to have. One thing that is good is that we found that following bolting down the heads, cam carriers and cams with the timing chains, we found the cam chains even with running the big CC head gaskets for compression reduction all ran exactly to spec whereas we thought they would have insufficient play, so deep joy, we re-installed the hydraulic chain tensioners so at least I won't be grovelling around under the car with feeler gauges after each thousand miles. When the engine is on the dyno one question to be answered is will the 36mil chokes in the Webers be sufficient to gain decent power. If it flattens off around say 51/2 or 6k we'll bung in some 38mil chokes and hope that this move will allow power into the 7's. I mentioned before I really didn't want to go to big 46's because with my G40 cams I'm not going to have much bottom end and the thought is going over to Jenvey injection, but we shall see.
So provided I get my engine back on the Friday or Saturday this will leave me 7 days to re-install the engine and gearbox, do all the hook ups, test drive, check for leaks - there won't be any then jump on the ferry to Northern Spain and head down to Estoril in Portugal for the 356 International meeting. OMG I can see a few 24hr work days heading my way.

Re: UK Outlaw

Posted: Sat Apr 20, 2024 2:39 pm
by Graham Kerr
Sorry folks, in my attepts to delete the engine pic attachment on my last post, it looks like I have added about 4 more. Possibly the esteemed administrators can delete all but one. Thankyou.

Re: UK Outlaw

Posted: Tue Apr 30, 2024 4:51 pm
by Graham Kerr
My ferry to Spain date of 5th May gets closer and closer and I'm still going flat out to get my 'wee beastie' finished. I finally got the engine on the dyno Friday last week. With street mufflers and a conservative timing set it pulled out 245 brake and 224 torque so I'm fairly happy with those figures although we would estimate 260 with my 'S' distributor and supertraps for exhausts. I hauled the engine back over last weekend and got to work on it first thing Monday, that's this week. Fitting the gearbox onto the engine was a pain, it just did not want to slide on. I pulled the clutch and flywheel out and checked everything matched which it did and then pulled all four studs from the engine. Surprise, the gearbox slipped straight on. With this I realised what may be happening. When I was getting the engine cases prepped for the 2.8 barrels I asked the machinist to timesert all the threads over M6. The four engine to gearbox threads had been timeserted but although I didn't think they would have been set in at an angle, the timeserts always have a hard shoulder and nothing like the soft introduction you would find with virgin metal. So I eased a couple of studs and left the other two out and bingo I had the box snuggly up against the engine. Great fun but this mucking around cost me best part of a day. Tuesday, today was get the coupled engine and box back in the car. I used a crane to take the weight and a good size trolley jack to juggle it in position. Putting a 911 engine and big 5 speed 911 gearbox into a 356 leaves very little room as I'm sure you can imagine. You have to get absolutely everything right on the money and one of the most difficult aspects of the job is simply getting the angle of the whole unit correct. However, a few cups of coffee and plenty of expletives later, it's all home, tightened down and ready for a few final hook ups. I will have to fabricate a new clutch cable bracket but apart from that I'm hoping all I shall be doing on Wednesday is straightforward stuff.