Polo motor build for junkyard coupe 58367

[Carrera_The_Kid]

Very Very nice Justin. I have shrouds for all my engines but will have to keep Gerd in mind for other sheet metal needs. His shroud looks very nice

Let us know when you hear more about the dolly, I might be interested in getting one and have a friend who would likely also take one. Funny, I have the original Porsche blue prints for these dollies

[merbesfield]

Wow! That thing is so cool. Artwork to a Porsche Geek.

[Bill Sargent]

Hi Justin,

Shroud looks great - much nicer than the one on my 2 liter 4 cam motor - it got knocked around some in its racing life. Have you made any modifications to the internal vaning in the shroud to account for the difference between the 4 cam vs Polo motor? I know Ibrahim modifies the vaning for pushrod motor use vs 4 cam. He has also done some shrouds for Polo motors being built for Michael Doyle.

Let me know when you get to the sheet metal on the motor and installing the motor in the car. I can probably share some knowledge based on the install of the 4 cam motor in my 59A cab a couple of weeks ago. First batch of photos over on the Registry site.

[Blechquäler]

Thank you so much Justin!
Please let me know when the parts arrived safely!
It's a pleisure for me that you and the others like it.
That engine will be a bomb when finished.

Joris, I think it would really be interesting to make those dollies, there are also people here who would love to have it in their garage.
It's so practical, it's small enogh to go through a normal door and it's very light because of the thin-wall tubes.


Thanks,
Gerd

[Carrera_The_Kid]

Gerd,

I can share the factory blue prints I have with you. I was thinking of making one myself but if you intend to make some that would be much easier. Let me know if I can help.

best,

Joris

[Blechquäler]

Sounds good Joris!
Will send you a p.m.

Best,
Gerd

[JTR70]

Hey Bill, No, Gerd builds his housings to exact specifications for an original 4-cam motor so I will modify the veins as necessary as locating and mounting this unit on my block progresses. You're a good man Bill, Thank you! I appreciate all of the help and advice you have given me through these past years.

That would be a nice offering, I think you guys would sell quite a few of those dolly's.

8/20/15
New 4-cam fan housing arrives from metal master Gerd Breuer.

Even more beautiful and impressive in person. My new Generator stand slipped right in with all mounting holes lining up perfectly.

Overall profile shape, spot-weld details and even brazed in throttle tube complete the authentic look and feel.

I don't know if he's stamping these (marked pattern)but it sure looks clean enough to have been. Again the radius profile on the corners just looks and feels right. Generator stand snugs up nice. I could not be happier with it Gerd!


Generator and fan assembly test fitted next.

While opening it up and test fitting I have such a new appreciation as to just how intricate all this ducting and fan fitment is.

On this rough initial mock-up the fan fit in there nicely and seemed to spin freely.

I was like a kid on Christmas morning today. All I did was stare and play with it. Thanks again Gerd for providing such a high quality unit. This housing is more than worthy of mounting atop a real 100K 4-cam motor; of which I know many of your satisfied customers are doing.

Okay, now I had to see it on the block.

A lot of careful planning and machining to get these two to fit snug ahead but the process will be fun.

Added the chain-boxes and Nigel's coil stand to help show what the eventual motor will look like.

Once the housing is set in the sweet spot and mounted to the block the lateral closing tins will be developed. I'll probably end up making the prototypes from fiberglass then once finished I'll send them over to Gerd for a final copy in Sheet steel.

Well, it was fun while it lasted but I didn't want this baby flash rusting so I broke it down and got it sealed in a coat of DP40.

Getting all the nooks and crannies in there took a while.

I'll shoot a light work coat of black on them tomorrow just for fun. The real work on the planning of the machining to the top of the block is next. Thanks for looking and thank you again Gerd...you're the man!
Justin

[Blechquäler]

Looks great Justin!!

[Blechquäler]

Show M

ust Go On....

[JTR70]

Thanks Gerd! I'm sure you'll have no problem finding those a home.
Justin

[neilb]

that cooling system looks fantastic Justin!

there are some really talented people around and Gerd is obviously one of them!

if only i had the money...

[jstenner]

Wicked!

Amazing work to all involved!!!

[molleur]

Work of art!

[roy mawbey]

Justin, just great pieces of work. A fantastic engineer for sure.

Roy

[JTR70]

Thanks a lot you guys! Absolutely, Gerds creation is now the crowning jewel of this project. Neil, I can't honestly afford this engine either come to think of it I really can't afford the whole car itself. The only way this is slowly happening for me is that I am able to build it a dime a time. I'm still paying the balance on my card for this shroud BTW. I wait for the swelling of my outstanding balances to go down and then I make the next big purchase. If I could really afford this project it would have been done several years ago.
Thanks again you guys!

Shroud in a quick workcoat of black "just to see"

Thanks to some measurements provided by Bill Sargent and Joris Koning I was able to determine that the unit needs to come down onto the block a good 2 inches for the center of the generator shaft and the center of the crank to match the distance of an original 4-cam motor. This is in consideration for eventual decklid clearance.

Initial mock-up shows the right side of the motor a natural aligned fit over the cylinders. I will have to incorporate an addition to the lower tin section to direct air into the stock rear mounted 911 oil cooler.

Quick mock up with head and cylinder. I can tell already that the eventual lower tin section is going to be a straight shot off of the edge of the housing making for a really nice contoured line.

Not all good news of course, as you can see the left side is badly misaligned an will require a bit more work but we'll eventually get air fed over to that last cylinder.

Learning a few things about this system along the way too. You can see here that the flow is divided into four so each bank, cylinder and head are fed air separately.

My machinist won't be able to mill the block until the first of October but my buddy Tony (master air-cooled mechanic) came by yesterday and started me on another "to do" list so we can determine the correct connecting rod length and get the Pauter rods for this engine ordered. Working on that next. Thanks for looking! Justin