SOT: Cayman X lives, take a ride!, 3.4 to 4.2L DFI 9A1 engine built our way! |
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SOT: Cayman X lives, take a ride!, 3.4 to 4.2L DFI 9A1 engine built our way! |
Jake Raby |
Mar 23 2012, 06:47 PM
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#1
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Engine Surgeon Group: Members Posts: 9,394 Joined: 31-August 03 From: Lost Member No.: 1,095 Region Association: South East States |
It may be water-cooled and modern, but I figured you guys would get a kick out of seeing what Blake and I have been working on along with Charles from LN Engineering since October of last year... Its still mid-engine, so don't bust my balls too bad :-)
We started with Charles' wife's track car, a 2010 Cayman S with a stock 3.4L 9A1 DFI engine. We stripped it out, carefully disassembled it and put it all back together again as a 4.2 liter beast... Its seen both bore and stroke increases and this engine currently displaces more volume than anything from the Porsche factory! So what if they have a 4.0?? Hell, we have a 4.2! We finally got it fired up yesterday and got it on the road and dyno today.. It keeps lighting the tires up on the rollers (needs more tire) and the PDK tranny has some issues with holding the power, but we should be able to solve that with some ECU flashes. Today it made 320 at the wheels with the tires lighting up and it still has the stock exhaust and stock ECU flash.. We completed this project with only one Porsche special tool set and no manual, because the manual doesn't exist.. All performance components were designed and built by LN Engineering or RED. I think we are on the leading edge :-) Here are some pictures of the internals. :Note the cylinders, pistons and rods in this engine are from the same materials we use in our Type 4/ 914 builds :-) 104mm big bore Nickies 9A1 DFI crankcase half. (IMG:http://www.914world.com/bbs2/uploads_offsite/fbcdn-sphotos-a.akamaihd.net-1095-1332550058.1.jpg) Stroker crank and billet connecting rods.. (IMG:http://www.914world.com/bbs2/uploads_offsite/fbcdn-sphotos-a.akamaihd.net-1095-1332550060.2.jpg) DFI piston, what a bitch these were to design, to include the hard anodized top ring land.. (IMG:http://www.914world.com/bbs2/uploads_offsite/fbcdn-sphotos-a.akamaihd.net-1095-1332550061.3.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/fbcdn-sphotos-a.akamaihd.net-1095-1332550061.4.jpg) ECU controlled multi-stage lube pump.. (IMG:http://www.914world.com/bbs2/uploads_offsite/fbcdn-sphotos-a.akamaihd.net-1095-1332550061.5.jpg) Inside the sump its a little different than a 914! (IMG:http://www.914world.com/bbs2/uploads_offsite/fbcdn-sphotos-a.akamaihd.net-1095-1332550062.6.jpg) Blake and I torquing the camshafts after setting valve timing.. What a bitch! (IMG:http://www.914world.com/bbs2/uploads_offsite/fbcdn-sphotos-a.akamaihd.net-1095-1332550062.7.jpg) Complete 4.2 liter DFI longblock (IMG:http://www.914world.com/bbs2/uploads_offsite/fbcdn-sphotos-a.akamaihd.net-1095-1332550063.8.jpg) Here is the complete beast ready for install back into Cayman X... (IMG:http://www.914world.com/bbs2/uploads_offsite/fbcdn-sphotos-a.akamaihd.net-1095-1332550063.9.jpg) Rumor has it there might be a challenge between Cayman X and a Cayman R at sometime in the future and a review of the two might just end up being put into print :-) And now here is the video... It is disgusting, even with the PSM it still roasts the tires and gets sideways in the first 3 gears.. Not too bad for the first generation of development for the 9A1 engine. Blake did one hell of a job assembling this one and overcoming the challenges.. http://youtu.be/62i7wYcHAYg https://www.youtube.com/watch?v=62i7wYcHAYg This post has been edited by SirAndy: Mar 23 2012, 08:06 PM |
Dr Evil |
Mar 25 2012, 08:15 AM
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#2
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Send me your transmission! Group: Members Posts: 23,002 Joined: 21-November 03 From: Loveland, OH 45140 Member No.: 1,372 Region Association: MidAtlantic Region |
Do you think they left power on the table because, like the 914, they didnt want the Cayman to compete with the 911?
I was watching some old Top Gear when the Cayman was first assessed and they showed how perfectly price, displacement, and power increased incrementally from Boxter to Cayman to 911. Surely by design. (IMG:style_emoticons/default/smile.gif) |
Jake Raby |
Mar 25 2012, 08:59 PM
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#3
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Engine Surgeon Group: Members Posts: 9,394 Joined: 31-August 03 From: Lost Member No.: 1,095 Region Association: South East States |
Do you think they left power on the table because, like the 914, they didnt want the Cayman to compete with the 911? I was watching some old Top Gear when the Cayman was first assessed and they showed how perfectly price, displacement, and power increased incrementally from Boxter to Cayman to 911. Surely by design. (IMG:style_emoticons/default/smile.gif) They left more on the table so the engine can evolve for a decade or so, making a tad more power every year.. Also, the Cayman has some self-imposed handicaps that reduce it's output over the flagship model. They are not dumb and they know that the more cars that can use the same components the easier it is to order huge quantities of one part and use it in 3-4 different vehicles all the same. This reduces costs and complexity and increases profit. Thats important when the accounting department is in charge of engineering :-0 They did this with the M96/M97 and now again with the 9A1, hell the 9A1 uses the early Boxster/ 996 connecting rod specifications and we used LN billet rods for an early Boxster in Cayman X's engine. This Cayman engine has some deficiencies that were imposed by the factory, to include the intake runner and plenum diameters. We made insane power even with these compromises but the next application of this engine won't be compromised by this. |
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