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 10 nearly 2 years and counting!-a stroker build. (Read 4063 times)
herdy 44
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nearly 2 years and counting!-a stroker build.
Sep 21st, 2019 at 7:28pm
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started an engine, transmission and torque tube recon and build in December 2017.
the engine is rebuilt , a newer lower mileage  gearbox has been tarted up and torque tube reconditioned.
I'm planning , when the car is up and running , to detail the build as it may be of some interest to someone.

the engine is 2.5 16v S , with alusil block bored out to 101mm.
it  is fitted with knife edged S2 crank, with JE forged pistons and turbo forged rods.
and S2 intake manifold.
windage ports have been machined into block.
the head has been polished and ported and valves lapped.
crank and flywheel lightened and balanced.

but hopefully it should be ready by the end of the year. Smiley
  
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T_Ryan.
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Re: nearly 2 years and counting!-a stroker build.
Reply #1 - Sep 22nd, 2019 at 12:24pm
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nice.

they make a stamped metal shield that runs above the headers for the ladymatic/auto cars that might help hold down the heat under the hood. it needs a little trim to mate back around the oil housing shield. power=heat that needs to be managed.
  
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slinger569
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Re: nearly 2 years and counting!-a stroker build.
Reply #2 - Sep 23rd, 2019 at 11:50am
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My hat off to you.. That looks amazing.  Cool
Good luck and keep us posted!
  

Dave
84 n/a - sold
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herdy 44
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Re: nearly 2 years and counting!-a stroker build.
Reply #3 - Sep 23rd, 2019 at 2:28pm
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thanks, i'll try and not set it on fire this time (happened after an engine mod. in 2013).

good idea on heat shield. i knocked up one , that protects the water pipe.
  
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jockellis
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Re: nearly 2 years and counting!-a stroker build.
Reply #4 - Sep 30th, 2019 at 2:31am
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Wondered if that blue car in the thumbnail was the one that burned.
  

Jock Ellis: White 1988 944 NA, '73 914 1.7 project, '72 parts car, '68 912 engine (basket case); Gone but not forgotten: '68 912, '72 914-6, '73 914 1.7, '64 1600 SC Coupe, '60 1600 Super Roadster
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Dave W
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Re: nearly 2 years and counting!-a stroker build.
Reply #5 - Sep 30th, 2019 at 5:27pm
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If those are the cast headers, I would unwrap them.  They can't handle the heat.  Ask me how I know.  Or just look at this pic. Smiley
  

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Dave - black 84 no longer exists. Sad 83 self destructed. All better now. Smiley
... Let's go hit some twisty roads! ...
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herdy 44
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Re: nearly 2 years and counting!-a stroker build.
Reply #6 - Oct 3rd, 2019 at 7:06pm
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ouch! how long were they wrapped for?
i believe my headers are made from a high quality steel.
and yes , it was the same car as in thumbnail.
  

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herdy 44
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Re: nearly 2 years and counting!-a stroker build.
Reply #7 - Oct 3rd, 2019 at 7:15pm
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this is a request to me ,from my brother who is dealing with the ECU. -

does anyone have


.bin and.xdf files for S and S2.
its apparently to change the maps for timing and fueling to accommodate  the stroker engine and higher compression rate (12.5)
the revs are being upped to 7200.
  
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herdy 44
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Re: nearly 2 years and counting!-a stroker build.
Reply #8 - Oct 19th, 2019 at 3:26pm
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i have fitted engine and gearbox and torque tube.
waiting to weld on lambda sensor mounts then fit exhaust.

hopefully running shortly.
  
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herdy 44
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Re: nearly 2 years and counting!-a stroker build.
Reply #9 - Nov 2nd, 2019 at 12:16pm
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finally started it on tuesday and hey presto ....runs great immediately.

however....... massive oil leak from oil pump.
so- oil pump off in car, and a total strip down of the front of the engine again!!!

anyone who has changed an oil pump with engine in car will know what an absolute joy it is.
worst job ive done on it in 30 years. had to drop the sump by around 5-10mm at front to get proper fitment with applying the loctite 574  for sealing.

the oil leak was, i believe caused by me applying the loctite but not thoroughly mixing in tube (it was a thin consistency initially), so it didnt cure in one particular place.

to add insult to injury, the thread on one of the belt cover bolts stripped, and i had to do a helicoil insert in it through the pump casing.

i hope to start it later in the next couple of days , but very apprehensive about anyoil pump leaks.

a  pump gasket would be so much easier than the loctite 

having spent the last 3 days solid on taking it apart and rebuilding it , i need some luck with a positive outcome.

but 944's are are an awesome car.
  
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herdy 44
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Re: nearly 2 years and counting!-a stroker build.
Reply #10 - Nov 9th, 2019 at 3:54pm
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no leaks !
however knocking from engine sump area once warm.
sounds like ROD KNOCK! Cheesy

before i tackle that , i took it out for a couple of miles to check the untested new gearbox. seems fine(phew)

car pulls like a train at lower revs . more lower end torque 
(a problem the 16v always had) and the  exhaust note sounds fantastic .

just stuck it up on jacks, again.
put engine support beam on and will start oil sump drop tomorrow.
i hope its the rod nuts hitting oil baffle, or tapping the bearing cradle ( i had to remove a lot of metal for the stroker crank arc to rotate freely) maybe when warm and expanded, its hitting???


will it ever end?
my long suffering wife thinks i enjoy any excuse to take it apart.- i dont.
all i want, is it to need filling up with fuel and a wash now and again. its winter now, but it had better be ready for next spring /summer here in the UK.

  
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herdy 44
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Re: nearly 2 years and counting!-a stroker build.
Reply #11 - Nov 10th, 2019 at 1:45pm
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some good news finally.

having taken the oil pan off, following clarks guide in which he  ranks it high on his "I don't want to do that job again" scale.

found a score near no.4 piston  on the journal cradle near the oil pickup caused by end cap hitting it. you can see by the photos how much material i had to remove for rotation of con rod. but was obviously not enough, although i did rotate crank on engine stand to make sure i didnt have this problem.
luckily , the cradle is reasonably soft and no drastic damage done.

now to take more material off and put it back together again, again!!! Smiley
at least it wasnt rod knock.
  
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herdy 44
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Re: nearly 2 years and counting!-a stroker build.
Reply #12 - Nov 20th, 2019 at 11:18am
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its still not quite 2 years yet, but close.
ive put it all back together, and as the mighty mr Clark wrote, it is a job on the "i dont want to ever do that again scale." Cheesy

but as i had hoped, it has cured the dreaded knocking sound.

  i took it for about a 50 mile run yesterday on the way back from its UK annual car inspection roadworthy inspection (MOT). which i'm glad to say passed with flying colours, thankfully. i took a quick pic when on inspection ramp.

the power especially now at low revs is quite remarkable now. and  ive not taken above 4500 revs just yet.

its probably around a 2.85 litre engine now instead of the 2.5 16v original.
with the head polished and ported, knife edged 3.0 litre S2 crank, lightened flywheel , JE forged pistons , turbo forged con rods and a compression ratio increased from 10.9:1  to 12.5:1.

the not so good news......another slight oil leak in vicinity of the oil pump again (vicinity, because with all belt covers on you cant tell)
enough to drip on undertray.  AAAAARRRRGGGHHHHH.

back on axle stands and another session on my back.
« Last Edit: Nov 23rd, 2019 at 8:33am by herdy 44 »  
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herdy 44
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Re: nearly 2 years and counting!-a stroker build.
Reply #13 - Jan 22nd, 2020 at 6:09pm
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finally got it on a dyno and was happy with the results.
a NA 16v 2.5 (S2 crank) with 218.8hp at the flywheel with 216 ft-lb torque .

now.......what next? Roll Eyes
  

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herdy 44
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Re: nearly 2 years and counting!-a stroker build.
Reply #14 - Mar 21st, 2020 at 3:56pm
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almost finished tinkering with it now.
  

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