8000 rpm/300 bhp 3.2 rebuild

[RobFrost]

You must be getting excited now... I'm excited for you.

Sent from my SM-G988B using Tapatalk

[Gary71]

Looks great Graham

I’m sure with judicious use of tie wraps the plug wires will be spot on.

[911hillclimber]

Rainbows!
Bought some v nice lead clips from Clewett, black of course, but look well engineered.

[911hillclimber]

Having a few days away totally in the Cotswolds has improved mu mojo, so spent the day continuing to 'wire' this 12 plug engine.

Neat n Tidy was the mantra, but also trying hard to keep these leads separated and away from the engine, no easy task.
Armed with a gazillion clips I used some spare orange 2 core 240V cable to help me plan the routes, and it is stiffer though at 7mm dia smaller than the real lead cable which I will use.
It is surprising how many unused tapped holes there are on this engine so managed to do it all without drilling the engine (!)

I think the pics say more than my clumsy words can.

Rocker cover bolts modified to carry the insulating cable clips:



Left hand side with all the routes sorted:



Right had side much harder:



This engine has to go in the chassis first and the front support bar slipped into place and onto the engine, so some of the looms has to be removable, rest is all 'on-board'.

Have bought a substantial crimping tool off ebay to crush the steel (!) coil pack terminals to the leads, and have ordered some spare ones for those I will cock-up.....

Expecting to have all the leads cut to length and in place by end of the weekend.

Also expecting to have the engine back in the car, box on with a fresh clutch friction disc and the 'ecu' in place somewhere in the cabin.
That means some fiddly wiring, not my favourite task.

Start-up getting close.

[hashman]

It looks great Graham, I hope it takes the seconds off your times .

Karl

[Gary71]

Looks super neat. Really nice

Can’t wait to hear it scream! Your problem will
be hanging onto those gears long past the point your brain is telling you to change up

[hot66]

For interest graham … I’m running the rsr style plug cap retainers on the lower plugs to make sure they don’t slip off.

https://patrickmotorsports.com/products/ignrsrsetpms

[911hillclimber]

I have 6 on the bench James.
They are awkward to fir with turbo lower covers and where my special insulators are on top of the cover bolts is where they are designed to fit!
The fit of the new plug caps to the iridium plugs is really tough and they are hard to push fitto befully engaged.
I do have a plan though!

[Mike911scrs]

"They are awkward to fir with turbo lower covers"

you need to cut out the covers, to fit the retainers and clear the end of the plug cap to stop the spark taking the easy route

[911hillclimber]

I've sorted it now Mike, but will do the deed tomorrow. Recovering now from bloody engine electrics...

Bet everyone is almost as sick of this engine wiring as I am.

BUT, now done, or at least the spark lead side is. Gave up trying to stop 12 leads from touching each other. I'm working on the 'dream' that with everything being new the spark will want to jump the plug and not to the engine. Time will tell.

First, bought a £37 crimping tool off ebay. It is utterly fantastic, and worth every penny. Could not do all this without it. The £4 green plastic crimping tool is best left as 'Not fit for Purpose'

Guessed the lead lengths I needed at 15 meters, and ended up with 2 meters over, could come in handy.

Lots and lots of hours have gone into this whole sparky affair and we are not done yet!
Plug clips to be done on the lower covers tomorrow, cam lube on the lobs and fit the covers for the last time. They didn't leak before, but crossing my fingers for this time.

I can then fit the ex manifolds and prep things for fitting the engine into the chassis before finishing off where to mount the control unit which might be trickier than it sounds.

[andytat]

It's looking great Graham!

[911hillclimber]

Thank you!
I need some encouragement..

Spent all day in the garage, but all progress. The lower plug retainers are sorted, the snakes nest of wires off the coils much neater, and I know where to install the control unit.

However...
There are a confusing number of wires in the loom and other packages for connecting to the engine/controller, so will need a clear head for that lot.

Getting close to installing the lot back in now I have my new clutch disc.

This disc is the original one I installed in 2010 when I got the car on the hills and it is looking 'ok' but too worn, so not bad wear, lasted about 500 miles!

Not sure if I feel excited, nervous or mad.

[Gary71]

Probably all three

Keep it going it looks great

[911hillclimber]

Major outage of the internet today and the PC probs yesterday, waiting for the 3rd issue to arrive on the computer front...
Let's see how far this post goes!

Friday, and the day in the garage to fit the engine and box back in and start linking up the essential connections.
Going to leave the smaller stuff until the engine runs in case it has to come out again and goes in the skip.

Cleaned the engine 'bay', got all the bits together, nut n bolts and prepped the clutch.



Checked the electrics again, 3rd time, and hoisted the engine off the stand after fitting the custom exhaust manifolds, tricky to make and 2 bolts very tricky to fit.







Pleasingly, all the clips and brackets for the wires all missed the chassis getting this fat engine into the skinny slot, the bay looks so big until the 3.2 is hovering above.
Touch at a time saw the engine in and the front cross member into place and all lightly buttoned-up. You do the bolts up tight when the box is attached and mounted.

The fresh clutch popped on and the box with it's WEVO shift gate fitted was cleaned externally and slipped into place just as it should. These jobs are sooo much easier using these tools.



The new ignition system sort of blends into the old look of the car, the dry sump is in.



Next will be the electrics of the control unit and getting that to be powered by the current dashboard which may be a challenge.

With that all done it is time to check the settings of the controller, pull the top 6 plugs out and churn the engine over to get oil everywhere.

And then...add fuel, and pray.

[Gary71]

Looks as good as ever Graham, and obviously more spark plugs leads = faster!