DDK - Die Deutschen Klassiker

......boat tailed, line honed, shuffle pinned, oil pressure relief by-pass, time serts, machined barrel decks, oil squirters, heads bored, high compression, counter weighted, balanced crank, blahdy blahdy blah ......

When I had my 2.4E engine rebuilt by Nick Fulljames at Redtek Engineering all the above went pretty much over my head.......although I've gained a bit of knowledge over the years I still have much to learn.

So, as I embark on the full and thorough rebuild of a 2.2S engine I thought I'd detail every single step, stage and process along the way (using Nick's words) along with the pros and cons of why each step is deemed necessary.......hopefully it'll become a good resource for anyone doing similar and I'll finally absorb what Nick's been explaining to me for the last 3 years!

A bit of background.....when I started my Mongrel project the plan was to utilise the majority of the 2.2S engine I'd inherited whilst taking it to 2.5 litres. As that project evolved I ended up not using much of the core components which left me with a pretty rare stack of parts.

Needing little more than engine cases and a crank, it was suggested that I build up another engine using the parts I had........it turned out that Nick had a pair of 2.2S cases and although reluctant to sell I managed to find a 2.4E engine he needs for a future project and after a little brokering everyone was happy! .......

....this will be a stock 2.2S engine, all of the core componets including cams, barrels and pistons etc are in good order and to spec and will be refinished as required. Each step and process will be detailed along the way.

As well as the 2.2S rebuild, Nick is rebuilding his 2.4E engine and I hope to be able to highlight some of the differences in specification between the two engine types.

Luckily the cases are 1970 items which date match all of the parts from my original engine. I've also sourced an alternative injection pump for my Mongrel project so I can retain the correct 70MY pump for this build.

The engine type for a 2.2S is 911/02....



Engine cases for early 2.2's are designated 2R and 3R and this is where my build starts......





Cheers,

Keep the pics and details coming Darren, it'll be great to read along with your build of the car....Mark..

Hear, hear - looking forward to it.

Nick was very helpful with mine too, it might be interesting to compare the 2.2T he did the machine work on and which I assembled here... http://goo.gl/9yTbc4 against yours as well - the full gamut!

Uk911 wrote:.....it'll be great to read.....

Thanks guys, although I seriously doubt that!

This won't be a terribly exciting thread, more a simple step by step guide explained in layman's terms.....hopefully it'll prove to be a thorough future resource for those doing similar.

It also won't be particularly quick thread as the 2.2S and 2.4E builds are being shoehorned in to an already busy workshop.........might just be long enough though for me to find a shell missing a drivetrain!

Cheers,

Darren,

You are a star, I will watch this with interest.

Mike B is right at the start with my own E engine. He has suggested putting in S pistons to give a bit more power (I wont go into the details of how we got to this) but leave everything else running as an E. So for my car this will mean more power which will be smooth and progressive. Exactly what I am looking for. Cant promise my foot will be smooth and progressive!

I will look forward to your updates.

TP81:

I DIY built an E 2.4 with mech injection and S P&B.

180 bhp and it drove an absolute dream. Deeply regret selling it all for £1000 a very long time ago.

It will be a very nice combo on the road.

Tp81 wrote: Mike B is right at the start with my own E engine.......So for my car this will mean more power which will be smooth and progressive.....

Obviously I'm no expert when it comes to how different 911's drive but can promise you'll be delighted with a 2.4E......the punchy cam gives you a mass of low down torque which continues right through the rev band, with low weight and sweet gearing the car is just sooo driveable and surprises many an S owner....

....but then there are other options!

The E cams and S p&b are the combo of choice. bob Watson told me to do this and he was right, pulled like a steam train from 2000 rpm, and in 3rd gear...fab!