About time I updated things
I never did make the Sept 2011 deadline due to a number of different things. Anyway, after a slight change in spec & long waits for parts to arrive my engine was finally completed & back in the car only a few days prior to Classic LeMans 2012 !
The aim was to rebuild the 2.4S engine as a strong reliable unit that was happy on european tours with the wife as it was blasting around the roads of North Yorkshire
Mike Bainbridge built the engine & he has been a star. He's had to put up with me on the phone almost daily with my usual ideas & questions
He has built a fabulous motor incorporating some mods for reliability & some for performance.
Anyway, here is a run down of the specs / parts etc . If not mentioned assume all parts blueprinted / etc & new bearings / bushings fitted though out. I'e also probo forgotten quite a few things
Spec
2.4S High Compression
Engine Build : Mike Bainbridge , MB Porsche Engineering
Engine Case Machine Work : Nik Fulljames RedTek
Pistons & Cylinders : Neil Bainbridge
Engine Dyno work : Neil Bainbridge
Case : Original Matching Numbers 7R case
Line Honed
Shuffle Pinned
Refaced barrel decks
Time sert head studs
Oil Bypass Mod
SC Oil Pump
Crank :
Balanced
New Aluminium Inter gear
Lightened Flywheel
Rods :
Stock Rods
ARP rod bolts
Pistons:
Custom Neil Bainbridge BS Motorsport Hi Comp 2.4S Pistons ( CR set @ 10.3:1)
Cylinders:
Original Birals, honed by BS Motorsport
Heads:
Stock S heads rebuilt with new valve guides
Valves back cut
EBS Racing HD Valve Springs
EBS Racing Titanium Retainers
Modified for twin plug
Turbo Rocker Covers
Cams:
Kent Cams ground from blanks GE40 ( Stock S )
Stock Rockers
Turbo-craft Rocker-Lockers
New Alloy inter gear,
New endless timing chains
New Chain ramps
Rebuilt chain tensioners
Modified Idler Arms
New S Shroud
RSR Plug wire holders
SSI’s modified for twin Lambdas
Stainless ‘stock’ Back box
Clewett Crank fire twin plug ignition
Daytona Sensors AFR dual digital readout & data logger
Daytona Sensors AFR warning system & shift light
Rebuilt and flowed MFI pump by MFIwerks to high comp 2.4S spec.
Injectors pressure tested & flowed
MFI Stacks & throttle bodies rebuild in 2010
Once Mike had competed the engine we got it shipped down to Neil Bainbridges for some dyno time. The advantage of Neils engine dyno is it can be used to 'run in' the motor and check all is OK. Neil ran the motor for the 5 hours or so on the running in program ( varies load & revs constantly through this period) . Once this was complete Neil did the power runs , altering ignition & fuelling between runs until an optimum point was reached to achieve the best power & torque safely
After all the time & effort I am really pleased with the end results.
Power : 215.7 bhp @ 7100 rpm ( stock 190)
Torque : 170.6 ft-lb ( 231.3 Nm) @ 5460 rpm ( stock 132)
In addition to the above, I had the gearbox rebuilt by Mike Bainbridge a few years ago so the drive train is now fully sorted
Additionally I have gone through the suspension again, fitting RSR Bilstein struts with custom valved inserts, Turbo tie rods, alloy rear arms etc to complement the elephant racing bushes all round. As mentioned earlier in this thread , the car is also running 3.2 brakes .
So ...... we got the car up & running only a few days before Classic LeMans 2012. I managed to get about 100 miles on the car before setting off
Had a few niggles on the trip , one of which required a bit of adjustment to the throttle linkages ( luckily I'm running a twin digital AFR data logger .. or paranoia box as it is now known
... which meant we could keep an eye on things ) . The other niggle was the RSR front struts required a pair of thin wheel spacers ( that I'd brought along just in case) to be fitted to prevent the wheel fowling the wishbones on lock & I needed to lift the front end by 1/2 inch or so as the car was running far too low with a full tank of fuel & 2 fat lads sat in the car
After almost 2000 miles & a little bit of adjustment & the motor is running better & better. It is a lot smoother than the previous engine & is way more flexible in terms of drivability , yet it still has the 'S' characteristic of coming on cam that I wanted to keep. Once on cam , it flies.
Really really pleased with this motor
Now just need to get some miles on the car !
I'll get some photos up once photobucket starts behaving itself again