Porsche Powered Mid-Engine Double Cab Build

[67dubcab]

The oil tank is located next to the engine like the stock Porsche set-up.
the thermostat is located even closer than stock Porsche 911 which is located in the rear wheel well.
The filter is a Canton with no by-pass, so should catch all before a short 18" hose run to the swirl part of the tank. All lines are -16, which are the same as the stock 911.

The pump is stock as are all the engine internals.

The running pressure is great, around 20psi at idle and builds nicely to 60+p.s.i. as r.p.m. increases, the engine also does not leak a drop, nor are there any leaks in the hose fittings.

I am going to gently warm up the engine and change out the oil to try to see if this metal making was a isolated non-damaging event (not likely).

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Porsche powered mid-engine double cab build
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[Stuartzickefoose]

might be worth running all the used oil through a paint filter/strainer a few times to see if you cant reuse it to flush the system, then once you have minimized metal flakes, put in a fresh 30 some quarts or whatever it takes. (26?)
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Stuart Zickefoose

2011 Jetta Sportwagen TDi 6 speed manual

206-841-7324
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[dubulup]

the stock 911 oil lines to and from the cooler are 1"? That seems quite large...but it sounds like your motor built proper oil pressure. Is a scavenger pump used?

If it's not too much trouble draw a quick flow diagram of your oiling system with the lengths of each segment (and size if there are some that are not -16). This could help troubleshoot...if there is an issue.

Is it similiar to this set up?

[67dubcab]

Hey Stuartzickefoose, I actually do some paint finish work and have those funnel strainer guys, I think what I have is a spun bearing or cam gear grinding or some other internal problem so I think the only thing to do is pull the motor and tear it apart (or it will keep eating itself).

I was thinking I may have to pull the engine some day and maybe do a top end to cure the common valve guide wear issue but was hoping for more than 30 miles till that day.

dubulup, the stock porsche oil lines are that large, they use 30mm fittings.
The stock porsche 3.2 has a single pump in the engine, one side pressure one scavenge. My layout for the lines is shorter than stock and uses the stock thermostat.
All the lines and fittings I used are -16 and the layout is mostly visible in my posted photos except the line from the scavenge side of the engine sump which I am happy with the layout verses the stock Porsche which is not very elegant.

I will try and post a schematic of the Porsche oil system if I can which I basically followed except my filter is not on the tank but mounted just off it.
The stock Porsche dry sump tank takes 9to 10 quarts per change with another 3 to 5 quarts left in the lines and coolers.
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Porsche powered mid-engine double cab build
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[Stuartzickefoose]

i kinda want to run extra oil in mine like this. major advantage is cooler oil temps, and longer periods between oil changes...and if you run a quart low, life will go on...
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Stuart Zickefoose

2011 Jetta Sportwagen TDi 6 speed manual

206-841-7324
[email protected]

[67dubcab]

Well, I am going to have to pull it all apart and tear into this engine.
I guess all the work Seth and I was not enough and now I need to rebuild the engine.
Well the short drive I did take proved the concept works well and with tuning and optimizing, (the next phase I was looking forward to) this will be truck I envisaged.
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[Stuartzickefoose]

[tlambert]

Sorry to hear about the engine issue.

I love what you have done with the project.

[Jacks]

[67dubcab]

Thanks all for the sympathy.
This engine fail is a big bummer. I was looking forward to the next phase of tuning all components and generally driving as I develop the chassis and systems, I hate going backwards. But, anger is a energy- so I am putting that into pulling the engine, fixing the problem and putting it back together better than before.

I am still not sure if I was sold a broken engine or it seized a bearing while sitting or it was something I did. I may not ever know for sure.

On the flip side the concept worked, the truck drove well out of the box(shop) and the few times I got on the gas it was a beast.
Moving forward......
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[germansupplyscott]

[67dubcab]

It is alive take two!
I found another 3.2 fairly close and picked it up. It had been sitting on a shelf for an unknown amount of time and was bought as a shop buy-out by the person I purchased it from, so no history, crap shoot engine.
The price was reasonable (for a Porsche!) and even if it was just a core it would be good for parts for the "glitter engine".

I took it down to a long block and put on my old engines intake/exhaust.
put it back together and fired it up today. So far so good, sounds O.K. and only has one minor oil leak, so back on the road!
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[tlambert]

Thats great. I know you have to be excited.

[BDubVdub]

Good news. I'm excited to see it on the road.

[67dubcab]

Thanks guys.
I am excited, though nervous. Watching the gauges- good oil pressure, 20p.s.i. at idle and up to 50/60 at redline.
No visible smoke, only the one small leak. I have not changed out the oil yet but will soon.

Some more on the road observations- power good but not over the top(future low boost turbo?
The shocks are awesome at crappy road control, ride is very controlled, could even go with more front spring rate, presently 180# with stock bay torsions(cut short for 4" narrowed beam).
I had a chance to bed in the brake pads and do some high speed stops-944 turbo Brembos work well. still tuning the Tilton proportioning valve, still needs more rear bias.
Shifting is notchy but I suspect I will get used to it, missed one 4th to 5th shift and caught 3rd, momentary 7000+ rev, no noticeable damage, but I am sure the rod bolts got just a bit longer.
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[Rustforlife]

Good luck on the 2nd engine....hope it works out.
I've been lurking on this build thread for a long time, and have to appreciate your dedication. And eye for quality and innovation! I would love to take your DC for a drive some time...lol.
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1956 Ragtop

[Twisted Minis]

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If you can find it cheaper, I can fix it.

[67dubcab]

Been awhile.
Daily driving and working out bugs. Right after Seth took those shots which were taken after working on some exhaust details the truck stopped after warming up to leave. At first I thought welding on the truck might have messed up the e.c.u but it turned out to be a dead fuel pump.
I went home and got a spare pump that came in a box of parts with the first engine I bought, put it in which is a pain since it is way back beside the fuel tank. hit the starter and 3.2 ltr of Porsche power is back from the dead- again. I let it idle and checked for leaks-gushing fuel from the pump!
The pump was leaking from the end-cap to body factory crimp seal, why someone would not just toss it as it mortally wounded. At least I knew it was the pump that was the initial fault. So a new pump goes in and away I go.
Some 2 or 300 miles later it dies again, tests for fuel pump power but no pressure, I am going to pull it soon and bench test, but I think it is dead.
I started a thread on the Porsche site Pelican Parts to see if anybody has some insight as to what is killing my fuel pumps.
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[Jacks]

^^^ you posted this at 9:11
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Jack Staggs
Actual name

[67dubcab]

I hope that brings me some good luck with this rig ,I could use it!

Thanks Rustforlife for kind words, I am hoping to drive it to the nor-cal treffen V.W Porsche show this sunday and also want to drive it to Busfest the following sunday, if you were to show up all the way from Texas then you can have a turn at the wheel.

So I had a chance to work on it and the recently new fuel pump is dead. I pulled the Canton Racing fuel filter and like the oil filter which destroyed my first engine it was bypassing the filter because the end caps were not fully sealed.
I put a new filter inline before the pump on the low pressure side and am running the Canton filter housing empty so I could hook it all back together.
When I get different high pressure filter I will plumb it in and throw the Canton filter in the recycling to be melted into something useful.

I put a new Bosch pump in, did the above mods, hit the starter and it lives again for the ??? time.
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