Polo motor build for junkyard coupe 58367

[JTR70]

Thank you Manolin, Exactly its all just for fun.

"I need to win the Euro lottery first or r.. a bank"
You and me both Per.
Thanks again you guys! Justin
6/16/15
Initial mock-up of 547 style "coil stand"


New stand was just quickly synched into approximate position with a single bolt so I could eye-ball it and take a few shots.

While I'm pretty sure it will clear my initial concern is the added final length this stand will put on this engine.

This is a mock-up polo motor in that 58 hotrod I'm working on and due to the rear suspension mods this unit sits back a bit farther than it would in a stock position. Even with this change there is a good 3.5 inches of clearance with the rear tray so I think it will workout okay.



I'll have to come up with my own adapter/ base plate as that push-rod version will never work. I'm thinking mine will have a V-taper Similar to the original 547 base. Like everything else it will evolve as it progresses. It was a fun distraction today.
Thanks for looking! Justin

[JOP]

Justin is there anything you dont have ?
How many of us have a extra mockup Polo engine, NOS dash etc to build our Porsches..... AND NOT using the parts!
Really coming together nice...keep flashing all those nice photos for us
/Per

[roy mawbey]

Justin,

I had to have an airbag module changed FOC by BMW today and whilst there took an old copy of a 'classic Porsche 'magazine to read. In it Rod Emory described the work he did in fitting two Polo engines into a a 58 coupe and a 56 speedster. Very interesting read. He fitted a 901 transmission with mated on 356 bellhousing and even shorter axles. The assembly was taken further forward in the 356 as well. He also named the guy who assembles the Polo engines for him in Oregon. He was using Weber carbs.

I sort of wanted to scan the pages for you but believe that is not allowed?.

Do you speak ever to Emory motorsports? He might well be good to speak to? He was getting around 200hp from memory.

Great photos above.

Roy

[Ryles]

I get on here at my lunch break most every day. Today... this last post cracked me up. They still get publicity? Maybe that was an old magazine?

Justin, I have enough popcorn for everyone. In your sweet diplomatic way, tell Roy, tell us all.

(This will go way off topic for hours if the chicken shit lurkers actually speak up, too.)

The Chinese have been ripping off ideas and patents for years.

[roy mawbey]

Ryles,

Just read your post above, now living in the back of beyond over here in the UK I have a question. Were your comments regarding Emory ?? The UK mag I read is some months old and maybe, with fully taking the text from memory, I must have got something really wrong there???

I thought Rod and I presume his late father were really good at their work on outlaw type cars, am I wrong there??

To me the 58 coupe and the speedster looked very nicely finished indeed from the photos.

I do have the mag outside in my BMW to correct my mistakes?

Roy




Roy

[JOP]

Roy, If you look at some older postings "Dean Polopolus falls victim ta an Outlaw" you will find some intressting story about Emory and the Polo engine......

[JTR70]

"Do you speak ever to Emory motorsports? He might well be good to speak to? He was getting around 200hp from memory."

Hey Roy,

No, I've never contacted them directly on anything and I don't foresee a need to as the project moves along. I'm in a really good spot at the moment. I have an aircooled engine builder Guru here locally in Tony Garcia and if I need more help than that I can ask the originator himself Dean Polopolus about any questions concerning his engine. With all the parts and prep that is going into it Dean said we could expect 230HP out of it. We'll see. The trans conversion itself is already very well along and is just a question of spare time and money to throw at it.
Justin

[JTR70]

7/12/15

Beginning to round up more 3.6 liter 964 engine components.

While looking for 964 cam towers and chainboxes I was fortunate enough to hook up with a really great guy by the name of Kevin Roush owner of GAS motorsports in Upland. I received my first parts package from him last week.

Very happy to of course get these big items in the purchased category.

but then my initial order soon turned to all the small hardware you don't even think twice about until its time to put the engine together.

I know I am still missing a good amount of small hardware but I did make a pretty good dent in it on this go around. I've found a few exploded parts diagrams of a 964 so I'll match that up with what I have and get my next purchase order ready.


Weird how a lot of parts came in all in one week. Dean brought me my new crank shaft yesterday when he picked up his car.

82mm Stroker crank. A beautiful piece and as long a throw as you can go without moving the oil pump outside of the motor.

Of course while Dean was here I was showing him all that I've gathered for this motor project so far. He really liked Nigel's V-drive casting and definitely approved of the 4-cam fan shroud going on as the photo above shows.
Thanks for looking! Justin

[JTR70]

7/14/15
Test fitting newer 964 parts to begin figuring out what needs to be done.
Dean's engine blocks are machined and set up to run earlier version 911 components so several minor changes will be necessary to get these parts to work. Fortunately the basic 911 design has only slightly changed in detail through the years so these parts still basically fit.


Much to my great relief the chain boxes bolted right up to the existing mounting holes. so the same basic pattern here.

Earlier 911 motors run an external oil line to feed the cams however these later chain boxes have an incorporated oil galley instead. You can see the opening of this passage peaking out here. We'll have to add and tap a feed for this galley on the engine block. This is probably going to be the most involved modification to run these later boxes.

Oil galley on the other side will also need some work but will only require an adaption.

embossment will need to be drilled and tapped to accept these keeper bolt for the lower chain rail.

Mocked up what I have of the tensioner assembly to get a better feel for it.

I only have a basic working knowledge of the 911 engine but I suspect I'll know this engine intimately before its all up and running.
Thanks for looking!
Justin

[roy mawbey]

Super photos Justin. Good start!

Roy

[Manolin]

I agree with Roy. This is a magnificent build thread.
Please keep us informed on the machine work to be carried out and where you'll have the work done. I remember the heads & what a nice job Walt did.
Thank you for taking the time with clear pictures as well.

[JOP]

Wow Justin,
That will be a small dynamite package that you are installing in the back of your 356
Is all the "Sharpie" drawings the extra material that needs to be carved of that lovely cast?
I am very envy of your motor build....because I WANT IT 2

[911quest]

Justin,

Curious why the use of the 964/993 timing chain housings?

Tony

[JTR70]

Thank you Roy and Manolin. Just like the car its going into to I wanted to share a detailed account of what it took to arrive at the finished product.
Hey Per, yes, the sharpie marks are a very conservative starting point for my buddy Bill to machine off. Tony, I wanted to run the latest and the greatest of the air-cooled 911 evolution. I'm already running 964 racing heads and cylinders so this choice just adds continuity to the long block. Thanks very much once again you guys!
Justin

[JTR70]

8/6/15

My new 4-cam fan housing ready to ship!

Metal Master Gerd Breuer just sent me these photos of my new housing that will be going out as soon as the paperwork clears customs. His workmanship and product presentation is nothing short of amazing!


Everything sure looks spot-on from all the photos I've ever seen of an original housing

Impressive inner vein construction.

He is truly an artist of the highest standard.

Here's Gerd's contact info if you're ever in need of one. The inlet ring is a new stamping he just finished to more accurately replicate the original.

I complimented him on his nicely replicated chassis dolly but he said its actually an original factory Porsche dolly he bought from Ebay that needed only minor repair. He's thinking about making these as well.

I drooled over these shots all afternoon, I hope you liked looking at them as much as I did. Even the back-drop and props where nice touch for the photos. Thanks again Gerd, I'm looking forward to getting it into my hands!!
Justin