Cairo's Six - 3.6 in and running great! Options

[Cairo94507]

My cylinder head temperature sensor arrived. Hopefully my "new-to-me" 993 harness arrives tomorrow. (IMG:style_emoticons/default/beerchug.gif)

[Cairo94507]

Yay!!! My chassis harness arrived; Wednesday we get to see what we can make of it. (IMG:style_emoticons/default/beerchug.gif)

[rick 918-S]

Dissecting a wiring harness can be a daunting task. (IMG:style_emoticons/default/blink.gif)

[Cairo94507]

We made some great progress on the wiring harness and the vacuum lines. What a difference the correct '95 3.6 harness makes! We started by connecting the MAF sensor and amazingly a lot of wires just kind of fell into place. We did lengthen the Idle Control Valve wires as we have moved that from on top of the engine to below the intake at the rear of the motor. The connectors we could not intuitively figure out we used the wiring diagram and sorted those.

The vacuum lines, and man, there is a lot of them, all made sense with a vacuum diagram. I think we have 2 vacuum lines that are still not connected but we know where they go.

We also routed the distributor "ozone" vent tube to what we felt was a good place.

I think in a couple weeks we should have it in the car. (IMG:style_emoticons/default/smile.gif)

Cylinder head temperature sensor. Don't worry, we routed it through the tin with a nice grommet to protect it.


What the heck is this and what does it do? @ClayPerrine @Steve

[Steve]

@Cairo94507 Unplug that goofy resistor. That’s part of the auxiliary heater fan
Otherwise, looking good!! Congrats!! Almost there!

[Cairo94507]

Great. Thank you Steve; I appreciate the help. (IMG:style_emoticons/default/beerchug.gif)

[ClayPerrine]

@Cairo94507 Unplug that goofy resistor. That’s part of the auxiliary heater fan
Otherwise, looking good!! Congrats!! Almost there!

(IMG:style_emoticons/default/agree.gif)

[Cairo94507]

Steve and Clay @Steve and @ClayPerrine - Thank you both so much for keeping us on the right track. We are getting closer and closer to being able to get the engine installed.

I just had the oil cooler shroud covered in Perlon (like the previous one was) and it came out great. I do not want to button that up until after we get her fired up and check for leaks (IMG:style_emoticons/default/yikes.gif)

[friethmiller]

(IMG:style_emoticons/default/popcorn[1].gif) Just enjoying your journey!

[Root_Werks]

(IMG:style_emoticons/default/popcorn[1].gif) Just enjoying your journey!

(IMG:style_emoticons/default/agree.gif)

Exactly what I was thinking!

[tygaboy]

I just had the oil cooler should covered in Perlon (like the previous one was) and it came out great. I do not want to button that up until after we get her fired up and check for leaks (IMG:style_emoticons/default/yikes.gif)

Hey! Let's see some pics of that shroud! (IMG:style_emoticons/default/poke.gif)

[Cairo94507]

@Tygaboy - Hi Chris- here you go:







I have to say, this shroud came out great. Thanks again to Chris for his mad fabrication skills and willingness to tackle this project. (IMG:style_emoticons/default/beerchug.gif)

[tygaboy]

Michael - That looks great! Thanks for the pics.

[Cairo94507]

Yesterday Greg and I, (really Greg) got the steel fuel line installed that takes fuel from the passenger side, (where we located the fuel filter) to the drivers side where the fuel rail input is located on the 3.6. Greg secured the line with nice rubber insulated clamps to keep it safe and secure. Now we need fittings to complete the fuel lines where they connect to the engine and fuel filter.

Then we tackled the "Mickey Mouse ears" we got from Patrick Motorsports. If I am being honest, I was utterly disappointed with this product. This PMS part sits atop the engine fan shroud where it is very visible, and connects the heater air supply tubes to the heat exchangers to get heat into the car. As received, this was a horrible fit. Both of the heater connection ports were poorly positioned, (IMHO (IMG:style_emoticons/default/confused24.gif) ) unless you wanted these heater tubes to look like some kind of wild tentacle abomination coming out the top of the engine. We decided to modify the right side (looking at the motor) to allow the hose to connect at a much lower angle to better fit the engine. The left side however, was far worse. That port was pointing almost straight up! All PMS had to do was rotate it 90 degrees and it would have been 100% better, allowing the heater tube to lay closer to the engine and look much better. Greg cut it off, rotated it, shortened it and welded it back on. Greg looked at the under side of this piece and you could see a good 3/8" of overlap from the mounting plate, obstructing the port; that was how it was received. This is designed to flow air- Greg "ported" both openings so they are smooth and unobstructed - it just looks right now- even though it will never be seen. This is more important, given the next change.

Then we had one more issue re the heat exchanger supply lines.... the hole through the engine tin is partially obstructed by the 3.6 design. Now our cars typically run 60mm heater tube. The 911 SC cars ran a 50mm heater tube and they also used a really nice reducer to go from 60mm to 50mm. We sourced some of those, (factory Porsche part) and bought 50mm hose. Now the tubes fit through the engine tin access holes with no problem. The added benefit is it also looks a whole lot nicer on the engine. We shot the Mickey Mouse ears black and put them on the engine and mocked up the lines- we both liked it and will call that done. Once everything is really dry we will permanently install the hoses and clamps.

Now don't get me wrong, I appreciate PMS making all these parts for the engine-swap crowd; I just wish in this case they would have spent an extra 10 minutes to look at it and make aesthetics a bigger part of the design calculus. (IMG:style_emoticons/default/dry.gif)

[Cairo94507]

Some additional pics my brother took- thank you Bob.

So, they look like Mickey Mouse ears, right?









Whose idea was this????




For a nice change of pace, a beautiful '74 with a special motor. One of Greg's cars and it shows.


Finally, that's the end of the day

[Steve]

Awesome thinking outside the box on this continuous challenge. Looks much better. The Mickey Mouse ears reminds me more of Hell boy. I Installed mine, but covered them up for now and blocked the holes. I will initially be running 1 3/4” MSDS headers and maybe seat heaters. I was also thinking it might be better to run a stock 914-4 heater fan to run the heat exchangers instead of the ears.

[technicalninja]

I "see" Tusken Sand Raider in the micky mouse ears...

I've been watching but not commenting.

The work is exquisite and doesn't require my opinions.

NICE!
(IMG:style_emoticons/default/first.gif)

[mb911]

Looking good. Isn’t amazing how we never leave these cars alone. My car is currently sort of running off megasquirt. Last year it ran pretty decent on carbs but I can’t leave well enough alone

[Shivers]

I have really enjoyed watching the "It takes a Village" progression of this project. Every little thing has been tidy. A beautiful job (IMG:style_emoticons/default/aktion035.gif)

[Cairo94507]

@Steve - Yeah, we had another Steve who did not like the Mouse ears and suggested we run a 4-cylinder electric fan. I just did not want to add another component to the engine bay- I am trying to keep it uncluttered. I think with the modified "ears" we are going to be happy and it should function fine. (IMG:style_emoticons/default/beerchug.gif)