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Old 02-12-2015, 08:41 PM   #1
Corbic
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Default EZ36 Swap into Porsche 911

Two years ago I realized my child hood dream of buying a Porsche 911. I spent over a year looking for the right car and finally settled on a 1985 911 3.2 with a recently rebuilt engine.

The car was a 3 owner deal that has spent it's whole life in sunny California. I took delivery a day after new years last year (2014).

Shortly after delivery on the way to winter storage in a climate controlled garage.




Slumbering on the 3rd floor till spring.







SPRING!!!



And a few hours after that photo was taken (that night)- a loud bang happened leaving the neighbors hood.





I pushed the car back in the driveway to deal with it in the morning.

Axle bolts fell out.




Welcome to POSrsche ownership. 2014 is going to Rawk.
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Old 02-12-2015, 08:48 PM   #2
Corbic
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Default EZ36 Swap into Porsche 911

2014 would be a true lesson in "Cause Race Car". Porsche is a company with unmatched racing heritage. The 911 has been one of the most successful chassis ever created. As a result Porsche has incorporated oodles of racing technology into their production cars. One of the most prominent is the dry sump oiling system found on all Air-Cooled 911s.

...the other is their usage of aluminum lug nuts.



Thank you whomever put these on with a torque-gun. See those two drill dots on the right photo? Those aren't mine... someone previously snapped an aluminum nut. I ordered some Guerrilla steal nuts. I then took the car to an independent for ANOTHER PPI and oil change. Car came back clean with the exception of a faulty heater motor, bad turn signal switch and burned out license plate lightbulb.


Last edited by Corbic; 02-14-2015 at 11:01 PM.
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Old 02-12-2015, 08:56 PM   #3
Corbic
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A month later I would leave work. While back up the engine made a sudden rattle at 3k. It sounded to me like it maybe the fan or fan belt so I get out with the car running to take a look. With the lid up and the car idling everything seemed fine. Nothing lose or making odd noises. I then... against my inner voice, decide to lean into the car while leaning back and trying to peer into the engine and goose the throttle. Just a quick jab to rev it up...

The car rev'd to 3k and make a "bang" followed by a "pop pop pop". I instantly killed the engine and called for a tow.

Nothing out of sort here -




Now the older 3.0 engines typically had timing chain tensioner failures. These items worked via springs while my Carrera 3.2 had hydraulic units. Rockers are also known to break taking out large portions of the valve train.

Drained the oil - FML.



Coworker left this on my desk a few days latter.



The car then sat for the rest of summer as I focused on dialing in my 240x and rebuilding my '72 Triumph Bonneville.

Last edited by Corbic; 02-12-2015 at 10:20 PM.
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Old 02-12-2015, 08:59 PM   #4
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Fall 2014. Dropping the engine.










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Old 02-12-2015, 09:09 PM   #5
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Stripped the engine.








BOOM-CHUCK-A-ROD



Mad props to my old man and best mate for helping man handle this bisch up on the stand. WTF to my brah-in-law and his "two finger" lift while [not] helping.


Last edited by Corbic; 02-12-2015 at 09:20 PM.
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Old 02-12-2015, 09:19 PM   #6
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Carnage.

One bent valve from the #4 that failed.
[IMG][/IMG]

Rod like noodles.








The culprit.



So basically this engine is part of the "930" engine family. Its a stroked version of the 3.0 engine found in the 911SC. The 3.2 also uses the same rods and crank as the 3.3l 930 turbo as well. The 930 Turbo using larger pistons with lower compression. "930 Rods" are beasts. Good for 500-700hp (reports very) but they have one huge problem. They use a TINNY 8mm bolt and because of the rods weight these bolts LOVE to snap at anything over 7k. Most recommend not taking stock engine over 6k.

The compounding issue is the rod bolts are a torque-to-yeild, aka "Stretch-Bolts". This makes them an idiotic pain in the ass to install correctly.

Thanks previous engine builder.

Last edited by Corbic; 02-12-2015 at 10:22 PM.
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Old 02-12-2015, 09:57 PM   #7
Corbic
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Default EZ36 Swap into Porsche 911

So I spent most of winter plotting and planning on what to do. In the last few years air-cooled Porsche prices have gone absolutely dwanky. The higher they go the more goobers are rushing in to buy an "investment" or "Get one before it's too late".

So while a 3.2 Carrera engine 3 years ago was about $5k, today they are going for $8-9k. A 3.0L SC engine was once a throwaway and the "big-upgrade" 964 3.6L that went for ~$7 are now $11-14k with twice the mileage.

For a power comparison.

3.0L = 180hp
3.2L = 210hp
3.6L = 250hp

All engines are very tunable.

So it was "Come to Jesus" time. I really really really wanted a 3.6l. If I'm spending all this money... what is half dozen more stacks to get more power and a better designed engine?




Any used engine was going to need a rebuild. A basic "bearings, gaskets and APR crap" build is $4-6k.

I began parting out my existing engine recouping roughly $4k.... One engine I was looking at was a running pull out 3.0L. Higher compression Euro-Spec with good history from a good owner. It was $5k and made 195bhp. A step down from what I had... and I still....



I finally came[lost] my senses. I bought this car to drive, not to "collect" or "invest in". Owning a A/C engine means forever being at it the mercy of Porsche's aftermarket industry and the skyrocketing prices. It means struggling to make power without dumping black-brief cases of money into it. It means battling 30-40 year old parts and metallurgical processes from half a century ago. These engines need massive amounts of specialized machining when rebuilt and have to be assembled at aerospace tolerances. A 3.6l was going to cost me almost $20k and it was simply not worth it to me for a meek 250-300hp.

I didn't want the "red-neck" SBC either. I love V-8s, I love torque and I'm a huge 'Merica Hell Yeah! guy, but I don't want a V8.

My Porsche 915 transmission is an older design. It's notoriously weak and really not suitable for anything over 300-400hp. I also view the LS1 as a sort of "automotive spam" (the food, not junk mail).

The LS1 is cheap, makes oodles of torque, is common and ... just like how Spam is cheap, has tons of filling calories and never goes bad. At the end of the day sometimes you want a steak even if it's more expensive, less filling and needs to be eaten the same day...

LS1 swaps while common also come with HUGE hurdles. The engines run hot making a radiator installation even harder. They really don't fit well. Specialized water pumps and accessories are necessary. I also have no desire to make my car sound like a 90's pick up truck with an exhaust leak...

So what is an exotic, inexpensive engine that suits a Porsche? Hmm, modern Porsche engines in the M96 family are still 5-6k and suffer from snapped rod bolts, block porosity, cracked leaves and everyones favorite - IMS failures.

Audi 4.2 V8?

Believe it or not Porsche actually experimented with this. Audi released their 3.6L V8 in 1988. During its development Porsche requested several to play with as they developed the next generation 911 (the 964 which was slated for 1989.

This is a pre-production 964 prototype fitted with the 3.6L. This car no longer exists.



This 959 chassis still exists. This was rumored to be the new 965 prototype (964 turbo).



Now after seeing Kpacz Boxsters projects I actually want a 4.2l Audi into my Boxster. That's a direct bolt-up affair to my transmission... so we'll do the Audi V8 another day.

Last edited by Corbic; 02-13-2015 at 08:04 AM.
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Old 02-12-2015, 10:04 PM   #8
Corbic
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Default EZ36 Swap into Porsche 911

So no Air-Cooled Porsche... no LS1, no Audi V8?

Then what? We'll I'm on NASIOC so I'm sure ya'll either read the thread title or guessed... Subaru Flat 6.


Porsche 914 (those ugly ones) with a EZ30..

https://www.youtube.com/watch?v=uod6avfs4AM

I originally started looking at the EZ30D with the intention of adding a small turbo. Engines are roughly $1k and Kennedy Engineered Products (KEP) makes an adapter to put a Subaru engine to my 915 transmission (~$550). Then I started looking at the EZ30(R). It adds VVL, 40hp and individual exhaust ports for roughly $600 more.

Then I scored an awesome deal - a EZ36D for just $2k shipped with all accessories and... and... AND ONLY 15K miles.


Last edited by Corbic; 02-13-2015 at 07:51 AM.
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Old 02-12-2015, 10:08 PM   #9
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Engined arrived yesterday -





We played with the engine a bit and my buddy made a great discovery. The Porsche 3.2 Throttle Body actually bolts right up to the EZ36 manifold.



Woot. Engine will be running a MS3.
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Old 02-12-2015, 11:22 PM   #10
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Great stuff! Can't wait to see future installments.
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Old 02-13-2015, 02:19 AM   #11
LucasBlack
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Very cool. I look forward to updates via here and the H6 Resource Thread.
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Old 02-13-2015, 10:51 AM   #12
Corbic
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Default EZ36 Swap into Porsche 911

I'll also be tracking the cost down to every bolt and washer. (As best I can).

Years ago I bought a '98 4Runner with records for everything done to it going back 10+ years. It was so cool. So I decided to see if I could do that myself. Gawd does it take discipline to write stuff down and save invoices.

Here is the initial cost estimate for the turbo EZ30(R).



I now have binders for the 911, Boxster and Tacoma.





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Last edited by Corbic; 02-13-2015 at 02:28 PM.
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Old 02-13-2015, 12:36 PM   #13
Corbic
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Default EZ36 Swap into Porsche 911

Over the winter I made a cool find at LKQ.



A Devek Porsche 928. Devek was once a popular tuner and someone running this decal was likely "in the know" back then. Unfortunately the car was so neglected nothing was worth pulling -








Well except for maybe the THREE PIECE WHEELS!




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Last edited by Corbic; 02-13-2015 at 02:27 PM.
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Old 02-13-2015, 12:40 PM   #14
Corbic
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Default EZ36 Swap into Porsche 911

Pulled them SOBs pronto. Cost me $98 (had to pay to get the tires pulled of).

Not bad for some classic 80's 3pc Epsilon wheels. Barrels are rough but the centers are great.







Clean wheels seem to go for for $2-3k depending on size and offset.


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Last edited by Corbic; 02-13-2015 at 12:52 PM.
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Old 02-13-2015, 12:49 PM   #15
Corbic
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Default EZ36 Swap into Porsche 911

930 with mega wide barrels in the Epsilon Conchi.




Screwing around when I changed the transmission on the Boxster. They clear the brakes but not the suspension.



Once I finish getting the 911 running again I'll decide if I want to keep the stock Carerra body panels or go to the 930 wide body. Then I can figure out what size barrels I need.


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Old 02-13-2015, 01:29 PM   #16
Patrick Olsen
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That's a helluva score on the wheels! Love the vintage ads!

Also cool info about the Audi V8 in the Porsche - I had never heard any of that before.
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Old 02-13-2015, 02:09 PM   #17
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You picked a nice one, I have a soft spot for guards red

subbing to see how this progresses!
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Old 02-14-2015, 10:08 PM   #18
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Subbed for future updates, cool project man
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Old 02-14-2015, 10:21 PM   #19
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Sí I want to follow this one. Lookin really good so far, cool swap plan!
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Old 02-14-2015, 11:43 PM   #20
Rogue_P
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Default EZ36 Swap into Porsche 911

Sub'd. Should be an interesting build.

Last edited by Rogue_P; 02-15-2015 at 09:23 AM.
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Old 02-18-2015, 03:18 PM   #21
innovation23
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Subbed with <3 from zilvia
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Old 02-20-2015, 12:01 AM   #22
Jazz30-06
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Subbed. Are you from MI by any chance?
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Old 02-20-2015, 12:26 AM   #23
Zefy
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cool. there is a local guy that did a ej25 (n/a) swap into his 911. He called it Porubi...

will be fun to see the progress.
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Old 02-20-2015, 01:38 AM   #24
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Old 02-20-2015, 09:28 AM   #25
Patrick Olsen
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^^^ Kind of, except the EG33 and EZ36 are pretty different animals.
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