Knackered old Porsche with loads of natural light - Boxster!
Discussion
skwdenyer said:
The next step is to get freon in the loop to cool the water in the charge cooler circuit 
That does involve carrying some sort of air-con compressor onboard though. It's a valid option though, Tesla use an AC Refrigerant/Battery Coolant heat exchanger to cool the battery when fast charging and in ICE world the Dodge Demon uses it's HVAC to chill the chargecooler coolant exactly as you describe. 
So I've skipped ahead in the plan a bit here as there were boxes of engine stuff all over my bench and I ended up with a spare day today that I wasn't expecting.... so I built the bottom end.
Piston and rod sub assem, specified ring gaps seemed enormous to me based on past experience so I've gapped them smaller hence expect them to make a bid for freedom through the side of the block or maybe just be fine and have an acceptable oil burn rate.
New high capacity oil pump, A4 oil pickup, billet timing gear and a posh bolt and friction washer to hold it all in place.
Also test fitted the sump, mainly to stop the engine dripping assembly lube onto the floor. The original oil level sensor mounting hole has been blanked off as it's not needed in this application.
Looks a lot like half an engine now!
Also fitted the oil filter / oil cooler and breather manifold assembly.
And fitted the head studs, partly to get the box off the bench and party to keep the blue roll cover in place
Finally I unboxed and arranged all the cylinder head/valve train bits ready to build that.
Really quite impressed with the tolerances on the pistons and rods. With a bit of mix and matching I was able to get all the clearances within a "blonde one" of each other and in the good bit of VAG spec.
Productive day all round really!
Piston and rod sub assem, specified ring gaps seemed enormous to me based on past experience so I've gapped them smaller hence expect them to make a bid for freedom through the side of the block or maybe just be fine and have an acceptable oil burn rate.
New high capacity oil pump, A4 oil pickup, billet timing gear and a posh bolt and friction washer to hold it all in place.
Also test fitted the sump, mainly to stop the engine dripping assembly lube onto the floor. The original oil level sensor mounting hole has been blanked off as it's not needed in this application.
Looks a lot like half an engine now!
Also fitted the oil filter / oil cooler and breather manifold assembly.
And fitted the head studs, partly to get the box off the bench and party to keep the blue roll cover in place
Finally I unboxed and arranged all the cylinder head/valve train bits ready to build that.
Really quite impressed with the tolerances on the pistons and rods. With a bit of mix and matching I was able to get all the clearances within a "blonde one" of each other and in the good bit of VAG spec.
Productive day all round really!
Edited by poppopbangbang on Sunday 24th September 22:44
Mikeeb said:
What ring gaps were they recommending?
Gap factor of 0.0080 per inch of bore for the top ring which in proper measurements works out at 0.65MM. The pistons are made from a pretty sensible alloy which by my maths (and given the pistons are cooled by oil squirters) shouldn't need much more than 0.45mm.... so I went in the middle.
poppopbangbang said:
Gap factor of 0.0080 per inch of bore for the top ring which in proper measurements works out at 0.65MM.
The pistons are made from a pretty sensible alloy which by my maths (and given the pistons are cooled by oil squirters) shouldn't need much more than 0.45mm.... so I went in the middle.
Gosh 8 thou/inch that is big! I thought a general rule of thumb was 4-5thou/inch?The pistons are made from a pretty sensible alloy which by my maths (and given the pistons are cooled by oil squirters) shouldn't need much more than 0.45mm.... so I went in the middle.
Edited by Mikeeb on Monday 25th September 23:41
Edited by Mikeeb on Tuesday 26th September 07:29
not seen one of those for a while!
Dr.Hellno said:
Those Venoms are flippin mental!!
You not interested in water/meth?
It'll have water/meth for the higher boost / sustained boost scenarios (it's rude not to!) but the charge cooler system will also have around 5L of coolant in circulation which is quite a bit of thermal mass on its own.You not interested in water/meth?
Few more bits done this evening, the bottom end pretty much done and just waiting for the head to go on!
Stock head gasket because MLM.
Water pump and belt tensioner on.
Oil cooler, breather and turbo oil feed fitted.
Quite a few AN Banjos appearing on this! I want all the lines to look as OE as possible so these will be boggo braided with crimped steel fittings like the standard ones. They might not look as flash as an anodised AN fitting but they're bomb proof and last forever (see JCB )
Made half a turbo oil return line.
All the valves are in so tomorrow I get the fantastically enjoyable job of trying to get the keepers in.
Still waiting on a few bits so this isn't going to be done and done any time soon but the vast majority of parts are now contained on the engine stand which means the workshop looks a bit tidier and my OCD is less tweaked
Stock head gasket because MLM.
Water pump and belt tensioner on.
Oil cooler, breather and turbo oil feed fitted.
Quite a few AN Banjos appearing on this! I want all the lines to look as OE as possible so these will be boggo braided with crimped steel fittings like the standard ones. They might not look as flash as an anodised AN fitting but they're bomb proof and last forever (see JCB
)Made half a turbo oil return line.
All the valves are in so tomorrow I get the fantastically enjoyable job of trying to get the keepers in.
Still waiting on a few bits so this isn't going to be done and done any time soon but the vast majority of parts are now contained on the engine stand which means the workshop looks a bit tidier and my OCD is less tweaked
What a great project. I have been on Pistonheads a while but mostly in the TVR section and this readers car bit is new to me. Discovered after the Bicester event. I need to write up one for my Boxster to balance it out a bit at the skill level. Latest entry would be, took out seat to replace clutch pedal spring. Gave up and put seat back in!
Looking forward to seeing what happens here.
Looking forward to seeing what happens here.
TV8 said:
What a great project. I have been on Pistonheads a while but mostly in the TVR section and this readers car bit is new to me. Discovered after the Bicester event. I need to write up one for my Boxster to balance it out a bit at the skill level. Latest entry would be, took out seat to replace clutch pedal spring. Gave up and put seat back in!
Looking forward to seeing what happens here.
To be fair, the clutch feel is much better without the spring Looking forward to seeing what happens here.
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