DDK - Die Deutschen Klassiker

Thanks for the nice comments Bob

Interior is definately on the cards but will have to wait until funds allow. I plan to do something along the lines of what Bootsy's done - protoipo, burbugring seats, RS door cards. ( http://www.ddk-online.com/phpBB2/viewto ... c&start=30 )

For the moment I've got a few mechanical things to sort out - tappets still noisy, rubbing sound from diff/driveshafts, and clunks from rear suspension when going over bumps

Long term I'm interested in the Elephant racing bushes, changing ratios in gearbox to improve acceleration, fitting larger brakes (boxter ones?), and then going for an engine swap - was previously going for a 993 3.6 but after reading Alan.uk's thread on his engine ( http://www.ddk-online.com/phpBB2/viewtopic.php?t=8541 ) I'm interested in something more in keeping with the period - subject to the necessary oooomph though, and also being reliable - this car is my daily driver

Cheers

Mark

And that's where it all went wrong......

Some of you may have seen my other thread (entitled Ohhhh Bugger...... and at http://www.ddk-online.com/phpBB2/viewtopic.php?t=8936 )

About a week after I got the car back the tappets seemed to be making a loud noise. I researched it all and adjusted them. They actually seemed a bit noisier after that so I did them again. This didn't really change anything. It was a tappetty knocking noise that went away when I drove faster, and was hard to hear when I turned the radio up. It was worrying me but not too mush as the car was performing better than ever - it was really running sweetly. Eventually I went into Zentrum, to get them to listen to it.

They said it wasn't tappets as the noise was too deep, but they felt it wasn't deep enough for the crank. Their money was on piston slap in one cylinder, but the only way to tell would be to do a strip-down, from the side of the engine making the noise and see what it was.

After the first day they'd got the engine out and started the strip-down. By the end of the second day they'd got one side's pistons and barrels off as well.

It wasn't piston slap - the only thing they could find was that one of the con-rods had a bit more lateral movement in it than the other two. When I wiggled it from side to side I was getting a sound similar to what i'd been ignoring for the previous 3 months.

The only way to get at the big end bearing was to split the case and strip the rest down - they needed to do that as well to make sure there wasn't something else causing the noise. Apart from some apparent blowing on one combustion chamber the engine looked good.

Her's a shot of my engine at the moment:-



With a closer shot of the top half



When they got it all apart the only thing they could find was scoring on the big end bearings - and then only on 2 or 3 of them. The associated crank journal (?) all seemed fine.

Here's a shot of the worst bearing:-



Looking through it all the engine was in great condition (apart from these bearings). One of the tensioners had been installed incorrectly but that will be rectified in the rebuild, as will the oil leaks and bearing shells.

Zentrum have now ordered all the necessary parts to start the rebuild and once these come in they'll get on with it.

I was toying with installing 98mm pistons & barrels but it's really opening another can of worms (would be better to install different cams to take advantage of it), and it's also additional expense I can't justify at the moment. I will be doing something like that later but for the moment it would be too much.

Will post some more pics when I see progress with the rebuild

Cheers

Mark

things are never straight forward are they!

At least you've got to the bottom of it and kept you head, was hoping to see it soon cruising the streets are Kirkby in Ashfield

Hi Mark,


I just caugth up with your latest posting on the thread. Good news is that the engine wasnt that bad- trouble is that lots of money will go into labour but at least you will know that it is done all right (zentrum's a lovely porsche shop in the style of old)

She is absolutely looking fantastic- finish, graphics, accents. Well done on your choice and picking your specialists wisely.

Take care


Bert

Thanks for the comments Bert - just looking forward to getting her back now.

Moving on - had a call yesterday that one of the lobes on the RH cam has gone - too worn. Got to have a new cam - other one is fine though.

It looks like the problem was all around cylinders 5 and 6 - there was a broken piston ring, excessive wear on two big end bearings, and worn camshaft lobe on No. 6

If we hadn't stripped it it would have got worse until something bad happened

THey ordered all the parts a couple of weeks ago, but when the small end bearings arrived last week they were the wrong size - slightly too big making them too tight a fit. Fresh ones are due to arrive on Thursday.

In the meantim they are cleaning everything up ready for the rebuild:-

This is a cool project car I love it.

Thanks Alam

Popped into Zentrum on Friday just to see how things were going - the new small end bushes had arrived and they were building it up. There were intending to do a late shift into Friday night and get it to the stage where it was ready for ancillaries only.

Had a good chat to Mike about it all - he seems about as excited as I am about getting it all back together. It should be ready early this week - I had a noise from the rear end when it was running as well - which is probably something to do with the drive-shafts so they're going to check that out as they are putting it all back in.

Should hpefully be driving it by the end of the week

At last!!!!!

Got the car back on Saturday morning. I was told on the Thursday I'd get it back on the Friday but I got a call from Mike and zentrum mid morning to say that they'd started it - it had run well and sounded sweet but he wasn't happy about oil pressure to one of the rockers.

He reckoned that this was why that particular lobe on the amshaft had worn out - this additional heat could have been the cause of all of the problems, come to think of it.

I was pretty miffed off as I'd been looking forward to it so much, and it wasn't clear from his conversation how eawsy it would be to sort - I was envisaging some sort of additional stripdown. Not a happy bunny.

Got a call from Mike later the same day to say he'd sorted it. It was an oil pipe that had corrosion on the inside, and which was therefore restricting the oil flow. They had to buy a tiny needle file and file out the corrosion and then go through it with an air hose and brake cleaner. When they'd done all that the oil pressure was fine. Yessssss!

Picked the car up Saturday morning - looking gorgeous and sounding it too now. The only problem was that in removing the exhaust a hole had come to light. There's not way I can justify a new silencer at the moment so some Gunsens Gum did the trick perfectly well.

The engine sounds beautifully smooth - really gorgeous. I'm under strict orders not to exceed 4000 revs for the first thousand miles - then I'll go back for another oil change, resetting of the emissions, and then I'll be able to do what I want.

It drives really nicely - as I approach 4K revs I can feel the torque building up so it's really frustrating to keep changing up.

Also I've read that it's important not to dwell on one rev range for too long a time at this stage so I'm continually taking it up and down the box and up and down the revs - to the extent where I'm slowing to 20 on a fast (empty) A Road so I can accelerate again. The kids don't think I'm stupid at all.

I'm thinking of doing my own intermediate oil change at 500 miles as well - will see how the mileage falls.

Unfortunately (!) I'm on holiday next week and surfing the week-end after so that might delay things - think I'll try and get an oil change in before surfing.

Mark

good news

Look forward to seeing the car in August

Are you going to Harewood beg June?

Not sure what harewood is or when it is? can you let me know

Sladey,
will we see you at the Ashby Folville meet June 13th ?
General
I'm trying to get loads of people there, and I've got promises from some of the London crowd
Cheers
Tim

sladey wrote:Not sure what harewood is or when it is? can you let me know

Harewood is the PCGB Yorkshire region show held @ Harewood house near Leeds on June 4th. I think there will be a couple of DDK'ers there ( Ian Donkin, Mick Cliff etc )

I'm sorry but I can't do the June 4th one as I'll be travelling back from holiday in Devon

Ashby Folville - I'm presuming Leicestershire - bugger - just checked and I'm in the middle of a two day conference in london - 13th - 14th June. That's a real shame cos I would have loved to have come along

Cheers

mark

MArk,

Great news! I know the feeling about starting it up the first time after a ££ rebuild!!!

They seemed to have done a great job; hope to meet up one day at one of the DDK meets!


Best regards,


Bert