8 cylinder front engine iconic vehicle
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By h2pmr
#169431
always wanted to use these 2 Smilies :popcorn: :eyepop: and this thread is looking perfect for them
By linderpat
#169514
car porn! NSFG (not safe for the garage!) Is this a different engine than what's you have in your car now?
By maddog2020
#169531
its actually the engine that was in my 928. After the conversion from Variocam, to regular cylinder heads and Simard cams, I sat on the project for years. In the course of my delay, a vendor came out with a new super duty street friendly clutch kit. I finally got it running last year, and lets just say that vendor's clutches are hard on engines, and not tested as well as they proclaim. 5 motors that I know of have been lunched by being guinea pigs for their "development" and I use that term as loosely as they claim their products to be "tested".

:hiding:

Also adding to the problem is that this clutch vendor got into yet another spat with another vendor who is a great friend. The clutch vendor decided to quit providing support for his kit because I was friends with the vendor he was pissed at. The company that makes some of the parts for the kit would not provide support because said vendor is not an authorized reseller for their products.
By MattiasH
#169539
Looks amazing!
Just out of curiosity, which bore size and stroke will this engine have?
By maddog2020
#169547
6.4 liters. 3.75 stroke and 4.095 bore. Static compression ratio of 12.4:1 Simard gun drilled billet cams intake .450 lift, 226 duration, exhaust .420 lift 220 duration LCA 110. heads have 968 intake valves (with INA Touareg lifters) and ported to 50mm round intake port for the 50mm ITB's. I'll be running it with a Link Thunder ecu, Injector Dynamics 750cc injectors & VAG COP for ignition.
Last edited by maddog2020 on Sun Dec 18, 2022 7:08 pm, edited 1 time in total.
MattiasH liked this
By Strosek Ultra
#170316
Titanium connecting rods, that seems expensive. Nice shiny Scat stroker crankshaft. I have a couple of those lying around.
The Scat Chevy syndrome has been discussed at length where the connecting rod sits offset in the piston. How is it in this case, are the crower rods made to sit in the center of the piston?
In my case with Scat Chevy 6 inch steel rods I solved the problem by turning the connecting rods 180 degrees around.
Åke
PS What happened to Mike Simard? I heard he went bankrupt.
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By maddog2020
#170397
the rods were a custom one off made set of crower titanium rods & since they didn't have stock available they made mine for the same price as off the shelf. The engine, was originally designed around oliver Ti rods, and so I wanted to stick with that in mind. I ran off the shelf Oliver rods for 30K miles with no issues and no abnormal wear on the pistons or cylinder walls.
By maddog2020
#171755
made some decent progress this weekend. Head gaskets came in so I was motivated to get out there and get some stuff done. I didn't get to the head gaskets as I wanted to get the timing belt tensioner and oil pump installed as well as some of the oil control bits for the sump.



This is the oil deflector setup from Kevin Johnson's crank scraper kit. The drains from the 5-8 cylinder head are aimed right at the spinning counterweights so I think these are a good addition. The 5-8 side of the block has all of the oil galleys in the way which is why Porsche didn't design the drains as they did on the 1-4 side.

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this is the drain that is aimed at the counterweights.

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This is one of the deflectors that redirects the oil straight down instead of onto the spinning counterweights.

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I decided to not use the crank scraper portion of the kit because I had the crank polished and I I decided that the gains from the scraper would be minimal.

I did decide to use the sump divider and the trap doors which I think works really well.
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Here are the pan mods to go along with the sump divider
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By maddog2020
#189567
Made some good progress today.

This is a backlit pic down through a gun drilled billet cam.
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Ready to do some cam timing
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Almost. A larger timing wheel allows you to get much more accurate cam timing.
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Couple of shots of the cams installed.
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Crumpler liked this
By maddog2020
#193303
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Top view of the AOS and oil filler cap
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Close up of my oil filler tube and AOS. I need to move the mounting bracket for the AOS up about 5mm
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Mini Setrab oil filter for startup and run in. comes apart easily and can be cleaned. above it is Han's sammich plate for the Bosch oil temp/pressure combo sensor.
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Last edited by maddog2020 on Mon Jan 09, 2023 10:15 am, edited 2 times in total.
hernanca liked this
By linderpat
#193353
I cannot wait to see this monster get done and see/hear it live! :rockon:
Strosek Ultra liked this
By maddog2020
#193457
two 12 hour days in the garage and not enough time to get the motor in the car. :banghead: :banghead:
By Stepson
#193609
His engine is sitting in the floor of his garage just grinning at him.......daring him to install it in the car and just waiting for it's next chance to send his OCD into outer space once again
SeanR liked this
By maddog2020
#195228
set the ITB's and fuel lines in to see how it looks with my aero tubing cross member. The factory crossmember would hit the fuel lines and not provide more room for the airbox.

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Making stuff that works is only half the battle. Making it look nice is the other half
MattiasH liked this
By Stepson
#195635
The blue tape is a classy look. I prefer silver duct tape, but the blue is nice. :hiding:
By maddog2020
#195675
Stepson wrote: Thu Jan 19, 2023 11:43 am The blue tape is a classy look. I prefer silver duct tape, but the blue is nice. :hiding:
The blue is to celebrate Sean's historic blue nuts
By Tony
#195701
This just crazy stuff. Love it.

Blue tape is easier to see and remove also..
By ALKada
#197135
Updates? Pics?
By maddog2020
#197184
just working on tedious minutia. This weekend is hopefully getting the exhaust buttoned up and getting her back on the ground for getting all the wiring and stuff finished up in the engine bay, along with heater hoses, radiator and new 5 speed condenser.

I'm waiting on cooling fans and some welding on the fan shroud followed by powder coating for the fan shroud as well the rest of my bracketry. Then I've also got the ecu & associated wiring to do with the CE and the harness for the trans as well as console wiring.

So, lots of stuff going on, just not any pics to show any of it. :burnout:
By linderpat
#200656
beautiful! :bowdown:
By amdavid
#200890
An absolute work of art! Wish you were my neighbor. :beerchug:
By Stepson
#200925
You wouldn't want to be his neighbor when he starts it, although I believe he tries to be a good neighbor (not starting too early in the morning nor later at night). It is BEASTLY sounding. It rattles windows, makes small children cry, women smile and men kneel in homage to the very sound. :)
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By maddog2020
#200959
Stepson wrote: Fri Feb 17, 2023 1:19 pm You wouldn't want to be his neighbor when he starts it, although I believe he tries to be a good neighbor (not starting too early in the morning nor later at night). It is BEASTLY sounding. It rattles windows, makes small children cry, women smile and men kneel in homage to the very sound. :)
Something like this?



must turn up the volume and have a sub to really appreciate it.
Ed Scherer liked this
By Stepson
#201874
Idle is very nice, but the sound during acceleration or by blipping the throttle creates that involuntary bystander smile and laughter that only accompanies unleashed RAW power
By maddog2020
#201905
the above video is what it will sound like again soon with much hotter cams, and itb's. It will sound amazing at full throttle.


this was 13 years ago with variable cam timing and stockish intake.

By Crumpler
#202073
I can’t believe how good that sounds.
What exhaust is on that Sterling?
By maddog2020
#202077
I started out with a set of 928 international stepped racing headers and reshaped the ends of the secondary's to tuck them up closer to the bellhousing. I wanted them tucked up as far as possible while also allowing the removal of the lower bellhousing. The headers are 1 3/4 stepped to 1 7/8 and then into a really nice slip collector. From there is a 3 " dual with a burns stainless X & borla XR1 race mufflers where the factory resonators were.

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By Crumpler
#202121
Well it’s a work of art that’s for sure.
I have the same set up from the x pipe back and mine does not even approach what you have going on there. That’s a testament to your headers or displacement or both. :drink:
By maddog2020
#202159
Crumpler wrote: Thu Feb 23, 2023 6:20 pm Well it’s a work of art that’s for sure.
I have the same set up from the x pipe back and mine does not even approach what you have going on there. That’s a testament to your headers or displacement or both. :drink:
Cams and cam timing can change the sound drastically. Variable cam timing on the 1st video really made it interesting at full throttle. the second video has even hotter cams, and itb's. I also had too much dwell on the coils, so it sounded much more choppy (harley like). After I got the dwell dialed back, even with the hotter cams I could get a smooth even idle at 450 rpms. Letting it idle that low would make normal drivability difficult off idle, so I will set the warm idle @ 800 rpm.
Crumpler liked this
By worf
#204277
A/C later?
By maddog2020
#204289
worf wrote: Wed Mar 08, 2023 9:58 pmA/C later?
This was a test fit for my new fan shroud and I'll be installing the new condenser and radiator again after I get the FOE harness installed as well as compressor, belts and other front of the engine stuff. I'm really happy with the engine lift bracket with the integrated AOS bracket, and also got the fuel hose clamps integrated as well. There were a lot of version 1 brackets and stuff that I had the time to rework.

One of the big changes was going with a dual pass setrab oil cooler, to include its own fan shroud with cooling fans and flaps with the goal of being able to cool the oil when stopped or not moving fast enough to generate air flow. I need the radiator installed to make sure the new oil cooler clears and my mounting brackets work well enough.
JMW928 liked this
By worf
#204290
maddog2020 wrote: Wed Mar 08, 2023 11:29 pm One of the big changes was going with a dual pass setrab oil cooler, to include its own fan shroud with cooling fans and flaps with the goal of being able to cool the oil when stopped or not moving fast enough to generate air flow.
That will be interesting to see.
By Tony
#205080
SeanR wrote:Looking good brother.

understatment of the year. :bowdown: :beerchug:
By maddog2020
#205283
this fuel line took an entire day. On the last round when the 928 was running, it was just loose, and I knew I had to secure it. It has 2 clamps to hold it behind the AOS bracket, and then I had this Y drilled so I could mount it to the timing belt cover. I had to make a 1/16" triangle shaped spacer to space the Y out from the cover so I could get the hoses on it, but also leave room for the dipstick... and then mark and drill 2 holes in my newly powder coated cam belt cover.
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Here is the dual pass cooler that will go under the radiator with it's mounting brackets.
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A close up of just the brackets
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mounted brackets
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shroud will have 3 fans as well as flaps to let air flow when the car is moving
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the shroud and fans are fairly compact, the bold is 81mm including the head
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the fan is a spal high torque fan made for motorcycles. torquey is an understatement. you better have this thing bolted down if you give it power, it almost took a chunk out of my thumb and shot across the garage floor.
milrad liked this
By maddog2020
#209145
pics of the oil cooler shroud and fans as it comes together. I need to cut holes for the flaps that will allow air flow when the car is moving. similar to the Hans fan shroud.
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Next will be making a bracket to hold up the rear of the front spoiler and front of belly pan. More than likely I will be using a half belly pan that stops at the mounting points on the engine support. headers are too large and bulky to work with any sort of belly pan.
worf liked this
By worf
#209181
maddog2020 wrote: Thu Apr 06, 2023 11:41 am headers are too large and bulky to work with any sort of belly pan.
You gonna keep the metal hind-pan for the cats? Or ain’t got no cats?
By maddog2020
#209425
outline for the holes for the flap. aluminum is 1/16 thick and is very sturdy. Lots of cutting and drilling planned for this weekend. rectangles will be covered with rubber flaps.

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By hernanca
#209465
maddog2020 wrote: Thu Apr 06, 2023 4:05 pm no room for the hind pan either.
Love the underpants photo! :thumbup:
By worf
#209478
hernanca wrote: Fri Apr 07, 2023 10:06 pm Love the underpants photo! :thumbup:
My…. Sterling, what big pipes you have. :lol2:

SG’s worried about the metal pan rubbing. I’m worried about the exhaust scraping the ground :tongue: No low rider will that be.

</hyperbole>
By worf
#209479
Hey, Sterling, you gonna put the lower bell housing on? Or are you just going to run it “commando?”

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