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

[Cairo94507]

The engine is in the car. It actually slipped right in without much bother. Greg had to loosen the engine tin on passenger side to get her in. We slipped the 993 chassis harness that connects the engine to the chassis in through the firewall in the same spot as the 3.2 harness entered and it fits nicely. Then hooked up both axles just because they were in the way and torqued them properly. Then Greg installed the breather hose from the oil tank filler to the engine.

The only concession I had to make to fit the air intake/MAF/filter where we wanted it to live was Greg had to remove the trunk torsion bars, (those puppies were under some serious tension). I will go with 2 hydraulic shocks to handle the trunk lid. I checked out Greg's 914-6 to see how they operate and they are nice. Removal of those 2 rods opened up enough space that the intake fits nicely and runs along the trunk bulkhead. We also removed the complete relay board assemble as we no longer needed that and it took up some serious space. I was actually bummed about that as I really like Auto Atlanta's (George's) new relay board cover and wanted to see that in the engine bay.

Overall, a really satisfying day; I am so so happy to see that engine in place. It's amazing how smoothly things go when you are working with a guy like Greg who knows what he is doing, has the tools to do it, and wants it to look as clean and tidy as possible.

Oh, we did de-boss the intake a bit to clean it up. Removed 3 large mounting tabs which held a large mounting bracket for some electrical connectors. Those connectors will live comfortably below the intake.

[sb914]

Nice job . You must be super happy.what a journey this car has had . I remember seeing it at Kent’s. They’re never finished. Looks tidy!

[Steve]

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Looks great!! I removed my torsion bars when I installed the 3.2 back in 2000. I am surprised you got the 3.2 in there with them installed. Mine will probably be end of July. Going on vacation for a couple of weeks.

[Maltese Falcon]

Keep your eyes on that contact area of the cone air filter and fuel-rail end; these cotton/alum screen filters are vulnerable to penetration and deforming when using in tight engine bays. Maybe a soft piece of foam-rubber there ¿
If your feeling creative; an isolation housing can be crafted>>just make sure enough air gets to it.

[tygaboy]

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and soon:
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[Maltese Falcon]

Isolation housing on my shop truck; made from plastic and is ducted into front grill>>fed with cold air. Cold air always better than (ambient) hot engine bay air...but just under the 914 grill=not bad at all !

[Cairo94507]

@Maltese Falcon

Yeah, that was our thought when noodling where it should live. Also, we will be adding a piece of rubber pipe to move the filter about 4" further out for more clearance. I just need to find that rubber pipe now.... I believe it is a 3 3/8" ID that we need. (IMG:style_emoticons/default/beerchug.gif)

[SirAndy]

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[930cabman]

Great news, which model shoe horn did you guys use?

[914dave]

The 3.6 looks awesome in there. I had to remove the torson bars for the 3.2 intake and fire suppression install. I use a KD tool telescoping prop for the rear lid. I didn't want to cut the seal for the struts. Since the front trunk is wet with the oil cooler and GT headlight kit. Needed a dry place for my clothes on long trips. Good luck with the rest of the install.

[Cairo94507]

Thanks guys; I appreciate the support. (IMG:style_emoticons/default/beerchug.gif)

[Cairo94507]

Yesterday was a busy day, but nothing that really photographs well. We got the fuel regulator side of the fuel rails connected but I need to get some proper clamps to complete that- I may have some in my parts stash. Sorry no photos. Please note the bottom of the engine has not really been cleaned as it pretty much lived on my garage floor or Greg's lift table prior to install. All that dirtiness is cosmoline. Once we get everything sorted, I will get to work cleaning it so it looks nicer- although part of me says, "If it has been on the engine since '95, protecting the case, why remove it?" It comes off easy enough as just using a plastic scraper or a finger nail removes it easily.

Then we measured several times for the intake pipe extension to move the filter cone about 5" closer to the drivers side of the car for better overall clearance. We did not install it after making the "pipe" we needed. But when we install it next time, it should look very clean as this will allow us to remove one adapter piece and 2 clamps. Stay tuned for that.

Then we figured out the oil inlet to the engine with Greg taking a stock 911 oil pipe and cutting/modifying it, (think hammer and block of wood (IMG:style_emoticons/default/smash.gif) ) and welding a nice fitting on the end to connect up to the thermostat oil line. I think Greg did an amazing job; it is tucked up perfectly where we wanted it so it does not interfere with anything and is in a well protected space.

We worked on a return oil line to the engine but in the end did not like the looks of it. So back to the drawing board on that - the final piece of the oil line puzzle. We want it to be a metal pipe coming from the engine, about 7" long and turning 90 degrees and terminating about 4" past the radius. It is a really tight space when you test fit the heat exchanger and our first attempt, though it certainly would have worked, just did not look like we envisioned. We need a pipe bender with a tight radius to make that happen. We shall continue to "noodle" on that.

The oil return line you see connected in the 2nd picture from the top, (with the hose clamp around it) is not the finished product. We just were connecting it to our initial engine return line for a length test. So no worries- the final one will be neat and the line will not have any radical bends in it.

Hopefully we will be back at it on Wednesday or Thursday. Cheers, Michael (IMG:style_emoticons/default/beerchug.gif)

[SirAndy]

Here's the hard line i used:
http://www.914world.com/bbs2/index.php?s=&...st&p=915814

I don't remember who made it (maybe PMS?), it was in the box of parts that came with the engine.
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[Cairo94507]

We will be back at it on Wednesday. I told Greg I could not make it Thursday as I wanted to be home in time for the debate! I think that may be entertaining. (IMG:style_emoticons/default/w00t.gif)

[930cabman]

I used a PMS setup but was not pleased with the hard line routing. Ended up cutting it apart and welding it up where it should have been in the first place. Cheap and simple and done

[Cairo94507]

Truth be told... I have not been impressed with PMS parts and certainly not their customer support which is woefully lacking. Given what they charge for parts, there is no excuse for that. (IMG:style_emoticons/default/dry.gif)

[SirAndy]

Truth be told... I have not been impressed with PMS parts and certainly not their customer support which is woefully lacking. Given what they charge for parts, there is no excuse for that. (IMG:style_emoticons/default/dry.gif)

For what it's worth, i feel the same way.

Don't get me wrong, i'm glad they are making parts available for our cars but once you spent the money with them, you cease to exist until your next order.
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[ClayPerrine]

We will be back at it on Wednesday. I told Greg I could not make it Thursday as I wanted to be home in time for the debate! I think that may be entertaining. (IMG:style_emoticons/default/w00t.gif)

[930cabman]

Truth be told... I have not been impressed with PMS parts and certainly not their customer support which is woefully lacking. Given what they charge for parts, there is no excuse for that. (IMG:style_emoticons/default/dry.gif)

For what it's worth, i feel the same way.

Don't get me wrong, i'm glad they are making parts available for our cars but once you spent the money with them, you cease to exist until your next order.
(IMG:style_emoticons/default/dry.gif)

More than a couple of us are in this boat. (IMG:style_emoticons/default/headbang.gif)

[Cairo94507]

OK, I sourced the pipe I need, 7/8" 0.065 wall mild steel (thanks Chris Baker for the referral to McMaster Carr. Then, Chris said he has a tubing bender that make the bend we need. Hopefully that pipe arrives at Chris' tomorrow or Wednesday. Then as soon as Chris is available my brother and I will buzz over to The Red Barn for nice little bend and to stretch the legs of his new (to him) 911 Turbo S Coupe. (IMG:style_emoticons/default/driving.gif) Where would I be without the assistance of guys like Greg, Chris, Clay, Steve, HB, my brother and a host of others? It takes a car community to do this stuff.