Flares....

[neilbardsley]

That is a work of art

Sent from my 22011119UY using Tapatalk

[Darren65]

What a horny motor!!

....like the owner

[Darren65]

That is a work of art

Very kind, thanks Neil

[matteo68]

Yup, 100% engine porn Darren!

[anka]

That is a work of art

Sent from my 22011119UY using Tapatalk

Totally agree amazing work Darren.

[jtparr]

....and most happy with the door cards fabricated by Gary. You see these fitted numerous ways and often with numerous screws!

That's probably due to the door cards becoming saggy with age due to only 3 screws originally being used to secure then along the length....but then 3 screws it was meant to be....



...one thing that gave me great pleasure was being able to use the door handles that were fitted in my 2.4E when I purchased it 15 years ago! They had been fitted to that car 15-20 years beforehand so now at least 30 years old and original items.

These handles are still available although the originals had a shiny finish to the plastic as opposed to the later productions which have a dull matt appearance...



...

Please line up those screws…..

[964RS]

Stunning car Darren, you relly do put the work in on your builds!

That first drive will be epic

[Darren65]

Thank you for the kind words Gents ....I've been dreaming of that first drive for some time!

Please line up those screws…..

....and never on a race car JP!

[Darren65]

Next the compromise - all projects have them!

The welded on brackets that hold the short arms on my car have been set slightly higher than normal.....this was introduced as standard on the subsequent 930 Turbo as it helps the car better deal with rear squat under hard acceleration and indeed racing teams modified the brackets later on to make them adjustable for their needs....

....the rear arms with torsion bars and coil overs is notoriously difficult to set up so I'm told and, taking into account my slight mod, I was recommended to use 935 type adjustable spring plates. There's a few option of these on the market and I went with Rebel Racing Products.....



....not the prettiest modification and visually not quite period correct although I'll console myself with the fact that it's an upgrade that would have certainly happened in the day.

Whilst performance driven and a definite benefit I'll need to get comfortable with this one visually.

....when at Centre Gravity Chris told me I needn't have worried!

[Darren65]

...and therefore these will be changed back to torsion bars to work with the coil overs. Just as they should be

How we do that I'm not quite sure....I have just received these very cool torsion bar/spring plate covers from Marek (early911parts - https://www.early911sregistry.org/forum ... er-for-RSR ) which were designed to work with needle roller bearings and homologated in late 1973 for the RSR...





....although the only car I've seen them fitted to is R6....





...I expect they were fitted to all 3.0RSR's at the outset although these days every car I've seen have reverted to regular spring plates and rubber bushes. I did take a look underneath every RSR at Le Mans Classic recently although that was a pointless exercise as race cars are never correct!....it could be that the needle bearing design wasn't as reliable, or offered no benefit over the standard rubber bushing or maybe parts weren't plentiful or it was just easier to go with the standard set-up?

If anyone can shed some light it would be nice to know?.....either way I'll be using these or standard spring plates and torsion bars in the near future.

Cheers,

[Darren65]

Nick has been sending through a number of pics of the engine assembly this week which has been exciting...









....

[Darren65]

...interesting point I learned from Gus Pfister regarding the injectors and posting here for reference....

"Hi Darren,
To your injector question the original RSR engines used injectors with DVO 460 or DVO 399 at a opening pressure of 15 to 18 bar whish had guided needles no longer available from Porsche or Bosch.

The street injectors has a BOSCH number EP/DC45R3 engraved. Bosch order number 0408 004 003 Porsche order number 901 110 271 00
opening pressure 15 to 18 bar. This are the only injectors available and are also used in RSR engines"



...interesting video of Gus showing the differences of the injectors here...

https://www.youtube.com/watch?v=NVdzWbIKpxM

....

[Darren65]

...we're not quite there yet as Nick is juggling this build with his commitments for Tuthills where he's currently setting up rally car after rally car (Nick waxing lyrical on how sweet the REEF exhaust systems are! )...

...and everything does take time....like, adapting CDI boxes....



...double checking and re-balancing lightweight flywheel....



...modification of the magnesium centre feed cam covers...







....although we are at the stage where the engine is now looking soooo good ...





....

[Darren65]

....what has held the engine up was an issue with camshafts which put us back a few months however the situation highlighted to me exactly why you use Nick Fulljames to build your engine...

...as I mentioned long back I purchased a set of original 3.0 RSR cams and sent these aware to be checked and refurbished...



...these were tested and matched against a profile the cam company had obtained long back and given a clean bill of health.

If you speak to most people they'll tell you RSR cams are no good for a road car although Nick disagrees and says it's set-up and fuelling that dictates how the car drives on the road.....that said, many engine builders will admit they never bother about fuelling on an RSR engine as no one cares what the engine does below 4,000 RPM!....

....when it came to timing the cams Nick wasn't happy and what followed was a long education process where Nick worked with the cam company to get exactly what he wanted....although there's only one 3.0RSR cam part number I'm aware of, I'm told there were three actual profiles used and from here there was much toing and froing between Nick and the cam company working on options. Nick explained it wasn't just about measuring certain points on the cam but also about the duration and lift etc as they went through the cycle, here he was talking about fractions of a millimetre to achieve the perfect result. The cam company were brilliant and patient throughout, at one point offering to supply new cams although it transpired my cams simply needed a tweak and all was well. Now fully timed up Nick tells me they're absolutely spot on and the cam company have gained a profile that will hopefully help others in the future ....



....my point here is where some engine builders might have just used the original cams and compromised on lower horse power and driveability, Nick did everything he possibly could to achieve the maximum best result

No doubt well worth the wait

Cheers,

[IanM]

Hi Darren, What is the engraved number on that new injector? The photo is not very clear but looks like EP/D0C ?