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This section is dedicated to Engine build and build data.
We will also chronicle current builds with commentary and photo's.
The tool room build is what this first chronicle will be titled. Tool Room implies a
certain level of quality, inspection and metrology. Measurements carried out with Sylvac Trimos, Zeiss Surfcom, Starrett CMM.
These techniques are used in a totally blueprinted application. We will take three of everything and focus on the culmination of the best of these parts to make one wide open throttle, tool room grade master piece.
The basic scope is to build an engine that will run WOT for prolonged periods at or near
the programmed rev limit.
While basic explanations will be provided with photos it is beyond the scope of these postings to explain every technique and purpose.
The fuel maps and boost character of this turbo motor will be custom and provided for optimization from dyno pulls. Final dyno maps will be provided to one of the major eeprom groups for custom programming of the final eeprom set, PowerChip, GIAC, etc..
Preliminary photos of the Exhaust Valve and Cylinder head candidates.
Of 16 factory, pulled, exhaust valves these are the closest in overall dimensions and weight. As seen lapped to a 16Ra surface; the final four candidates will be lapped to 4-6Ra. The final lapping will be done once coated.
The grinds were done in house of course. And to further match the final four will be done on a precision grinder and will be fixtured with a motorized 5C Harig Spin Indexer. The lash heads will be 2-3Ra and matched to each lifter.
The cylinder head shown is the candidate of three chosen for now, and started life as a 4452 head. As you can see, and without any further lapping to the valve seats, the surface contact of our first test is a near perfect angular contact to the seat.
This head has completely worn out guides but the seats are in remarkably good condition.
The seats will also be lapped to 4-6Ra and valve matched.
The valve guides will be machined in house from a spec milled, powder centered bronze bar, sized and lapped.
CAM Shaft
Factory CAM Shaft. Of the three cam shafts this is the one that was nearly perfect in every aspect.
The two other candidates, one had worn journals and the other of the three had lobe pitting.
The cam shaft with the lobe pitting was a 52 cam and was dimensionally perfect. I suspect that Porsche let this cam and others like it pass QA. The lifters at those two lobe positions had surface damage.
This cam candidate has a 12 Ra micro finish on the journals. The lobe peak, base radii and key locations on the lobes have been measured and polish to 12-16Ra finish. The final finish on the peaks will be 2-3Ra target. The journals are not slated for coating at present, but this may change depending on the serviceability and finish to the cam house bearing surfaces.
The spec on the journals are 0 to -.00002 O.D. of each other, and the lift measured +/- .0001..
Once finished should be nice.
 
Crank Shaft
Crank Pins and Journals have been lapped to size and polished. The crank is ready for surf analysis to measure surface uniformity and finish.
Crank oil system is currently under address.
Photos will be posted soon.
These photos are dynamic and will change as will as the content as the build progresses.
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