Cairo's Six - 3.6 in and running great! Options

[Cairo94507]

Hi Everyone -

Some may be aware I recently bought the '95 993 3.6 motor Chris (Tygaboy) had for sale. I must have looked at his ad a 100 times (IMG:style_emoticons/default/drooley.gif) and finally could not resist. Had it not been Chris and pretty local to me I probably would have passed.

The 3.6 has approximately 18K miles on it (IMG:style_emoticons/default/piratenanner.gif) and came out of the 993 in 1997 following an accident. The engine was properly stored with rocker arms loosed and oil poured in the cylinders and turned over regularly. I pulled the plugs and it turned over like a new engine. Squirted some oil in, reinstalled the plugs and have turned it over a few times since it came to my garage patiently awaiting the swap.

Greg T. (master mechanic/technician/body man and painter) (IMG:style_emoticons/default/pray.gif) and a very good friend agreed to tackle this project at his garage. So on Friday (2/16/24), we drove to Greg's (it ran great) and a short 5+ hours later the 3.2 was out. We took our time and the biggest hassle was pulling the wiring harness for the 3.2 out of the car without damaging anything. (IMG:style_emoticons/default/biggrin.gif)

The next day we trailered my Six in Greg's enclosed trailer, pulled by his wife's beautiful Dodge Ram diesel, to the Red Barn! Yes, Chris, (master fabricator if ever there was one) another great guy and good friend @Tygaboy agreed to do some metal fabrication as a part of this swap. After seeing Chris' skills on multiple projects, (IMG:style_emoticons/default/smilie_pokal.gif) I knew if someone was going to be cutting (IMG:style_emoticons/default/sawzall-smiley.gif) and welding (IMG:style_emoticons/default/welder.gif) on my car. I really wanted it to be him. (IMG:style_emoticons/default/pray.gif)

After looking at the current oil cooler setup, (IMG:style_emoticons/default/idea.gif) it was decided to leave my existing GT style oil cooler and add the 2 Spal 6.5" fans and see how that works. My 3.2 stayed cool while driving unless I got in stop 'n go traffic (What? None of that in the Bay Area!) and then the temperature would creep up. We will relocate my oil cooler thermostat from the front trunk (where the factory installed them in the GT cars (IMG:style_emoticons/default/confused24.gif) ) to the engine firewall- where we all agreed it belonged. I have to give Chris credit for this plan as I originally was going to swap in a larger oil cooler and open the nose panel of my car up (IMG:style_emoticons/default/sawzall-smiley.gif) to mate to the new cooler with a nice duct (IMG:style_emoticons/default/welder.gif) . Chris pulled me back from the edge and said he believed cutting the nose panel out may not be necessary once the fans are installed.

Of course that is not all Chris is doing. My car has factory, non-retractible, seat belts and my brother and I prefer retractible belts. So we are installing retractible belts. Chris will do the fabrication; he did this to his LS car and it works flawlessly.

OK, here are some pictures to get this thread rolling; I hope you enjoy following along as this stuff happens.

Again, a sincere thanks (IMG:style_emoticons/default/tiphat2.gif) to Greg T, Chris B., my brother Bob, HB (2 914 owner and good friend), for their support and encouragement. And thanks to anyone who has done a 3.6 swap into a 914 and posted about it so we have a road map. I will document our project to hopefully make it easier for others to do the same.

Cheers- Michael (IMG:style_emoticons/default/beerchug.gif)

[rick 918-S]

What size line do you have running up to the cooler? I have to plan this out for my 6. It had a front cool but was removed before I ended up with it.

[tygaboy]

What size line do you have running up to the cooler? I have to plan this out for my 6. It had a front cool but was removed before I ended up with it.

@rick 918-S Michael's car has -12 lines. I assume that's standard for the 3.2/3.6 but I'd defer to those more knowledgable.

[rick 918-S]

What size line do you have running up to the cooler? I have to plan this out for my 6. It had a front cool but was removed before I ended up with it.

@rick 918-S Michael's car has -12 lines. I assume that's standard for the 3.2/3.6 but I'd defer to those more knowledgable.

Thanks. I have been researching hard line stuff but haven't gotten as far as sizing.

[tygaboy]

Fan mount/lower shroud V2 looks like it's a winner. I still need to add the fasteners for the upper fan mounts but in all, I'm liking it.
This component is far enough along that I can get started on the main shroud design.

[Cairo94507]

Loving it! This is exactly why I knew Chris and the Red Barn were where I wanted to be (IMG:style_emoticons/default/smilie_pokal.gif) . This is going to work very, very, nicely. I am getting excited to be able to go pick her up and move on to the next stage of this project. (IMG:style_emoticons/default/beerchug.gif)

[SirAndy]

What size line do you have running up to the cooler? I have to plan this out for my 6. It had a front cool but was removed before I ended up with it.

@rick 918-S Michael's car has -12 lines. I assume that's standard for the 3.2/3.6 but I'd defer to those more knowledgable.

I'm running -12 on my car, should be plenty.
(IMG:style_emoticons/default/bye1.gif)

[Cairo94507]

@SirAndy - Thanks Andy- That makes me feel even more comfortable with this set-up. (IMG:style_emoticons/default/beerchug.gif)

[Cairo94507]

Oh, and just to follow up, the 3.2 arrived safe and sound to the new owner. I breathed a sigh of relief when he let me know. (IMG:style_emoticons/default/beerchug.gif)

[roundtwo]

Fan mount/lower shroud V2 looks like it's a winner. I still need to add the fasteners for the upper fan mounts but in all, I'm liking it.
This component is far enough along that I can get started on the main shroud design.

WOW very slick. Looks fantastic and FUNCTIONAL!!

[tygaboy]

I'm reusing the pre-existing cooler mounting holes but they were so close to that drop-down in the nose of the chassis that even a small-ish washer wasn't a happy fit.

So for Michael, even the washers are custom. (IMG:style_emoticons/default/laugh.gif) (IMG:style_emoticons/default/shades.gif)

[Cairo94507]

(IMG:style_emoticons/default/smilie_pokal.gif) (IMG:style_emoticons/default/beerchug.gif)

[930cabman]

I'm reusing the pre-existing cooler mounting holes but they were so close to that drop-down in the nose of the chassis that even a small-ish washer wasn't a happy fit.

So for Michael, even the washers are custom. (IMG:style_emoticons/default/laugh.gif) (IMG:style_emoticons/default/shades.gif)

With the /6 conversion I have been working on, it appears the same. So many custom bits. How would anybody estimate the $$ for one of these?

labor of love for sure

[tygaboy]

Driver's side seatbelt retractor mount:
- area prepped (welding jacket protecting things)
- secured with a couple self tapping screws
- TIG welded in place
Note that unwelded hole gets drilled out for the loacting pin on the back side of the retractor.

[roundtwo]

Diggin' the whole oil cooler system... (IMG:style_emoticons/default/piratenanner.gif)

For us off the shelf folks might something like this be an option for the oil cooler set up?

https://www.pegasusautoracing.com/productde...asp?RecID=26672

[tygaboy]

Really? No one? Really? I need you folks to pay more attention!! (IMG:style_emoticons/default/poke.gif)
Not one of you pointed out that if I didn't want to have those fan mounts poking up above the top of the cooler cover, all I had to do was ROTATE THE !@*%($# FANS!!!

I almost pee'd my pants laughing when I realized I'd totally missed this, created more work for myself, etc. Good thing I don't do this as my day job.

[tygaboy]

I used the redo as an opportunity to make a couple other updates:
- the whole thing is wider and it now competely encloses the cooler
- the width eliminates a minor air gap at the outer, lower corners between the cooler and this mount
- I oriented the fans so the wires all point in the best direction
In all, much better...

[Cairo94507]

If I had 1 year to design this, I couldn't. Chris is the best. (IMG:style_emoticons/default/smilie_pokal.gif) I love this cooler/fan. (IMG:style_emoticons/default/beerchug.gif)

[tygaboy]

I'll be posting this on my channel at some point in the future but figured you folks would enjoy keeping up with progress closer to real-time.

https://www.youtube.com/watch?v=dJHU7KiJnFI

[horizontally-opposed]

I used the redo as an opportunity to make a couple other updates:
- the whole thing is wider and it now competely encloses the cooler
- the width eliminates a minor air gap at the outer, lower corners between the cooler and this mount
- I oriented the fans so the wires all point in the best direction
In all, much better...

Simply beautiful work…

[JmuRiz]

Good looking work!! Let me know if you plan on selling off the old shroud bits...if the red barn makes a new taller/wider version.