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By h2pmr
#97825
many years ago a friend of mine did some work for me and asked if he could have the S4 engine block i was going to throw out as payment to make a coffee table, which was a good deal for me.

fast forward to last week and i asked him how the S4 coffee table was doing, his reply was along the lines of what do women know about what looks good as a coffee table, so the block has been in his garage untouched ever since, he needed the space so i got it back for £20.

so its now on an engine stand, clean and just needs building.

it will never be good enough to be put in a car so i will be building an "exploded" S4 engine.

will include heads, cams and chains, cam sprockets, rocker covers, intake manifold, throttle body, coolant bridge, sump, exhaust manifolds, water pump, crank pulley and sump + a few other small castings.

all held in exploded position with either longer bolts or threaded bar and nuts either side of the casting.

just need to work out what looks good spacing wise and either get a local machine shop to cut the coolant bridge and intake manifold right down the middle so can bolt it straight up from the head mounts or make N shaped brackets to hold them in mid air.

wanted to test fit the heads but hardware store did not have any threaded bar with the head bolt thread, so test fitting water pump pictured, the gap between water pump and block is 1.5" now, what do you guys think of spacing, more or less?

with it all just bolted together, it can be easily stripped down for powder coating and transport

depending on how it turns out it will be the base for a large coffee table or a folly.
only time will tell

cheers
Phil
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By h2pmr
#97834
a very quick mock up, still needs a lot of cleaning and getting the spacing looking right and equal for all components + more threaded bar but its the general look i had in my minds eye :thumbup:
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By worf
#97863
Great concept. Can’t wait to see the final product.
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By h2pmr
#97873
Majestic Moose wrote:That will be very cool.
Image
before i started this that was the only picture i could find of an exploded engine, so thought it time for an S4 version.

and i have just realised that what i thought were just black threaded bar on the above picture are actually steel tubes that slides over the threaded bar and so can be tightened down to compress the parts together and give better rigidity.

i was just going to use a nut either side of the components, as i my pictures

steel tube added to the shopping list

cheers
Phil
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By Geza-aka-Zombo
#97888
Can't wait to see it completed. Best of luck.
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By h2pmr
#98189
local hardware store has perfect size of tubing to go over the threaded bars, but had to order the threaded bar for the head bolt thread.
i think i have found a machine shop who can cut the coolant bridge in half so i can bolt each half straight up from the head.

but the intake manifold is staying in one piece, with the side covers exploded out so the innards of the intake can be seen.

forget the crank sprocket in the picture, i got it out a box of parts and then realized no crank fitted.....

so should get a little further at the weekend.

cheers
Phil
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By linderpat
#98235
wow, that's really cool! Someday when you tire of it, one of us 928 addicts will pay stoopid money for it :biggrin: :bigok:
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By h2pmr
#98884
tubing over the threaded bar looks far better than just a nut either side of the parts.
but by the time its finished and i have split the 2 half's of the block it will be about 4ft tall
so will need to make a stand out of box section and bolt it through the engine mount holes.

looking more like a folly but am enjoying doing it.

cheers
Phil
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By h2pmr
#99127
one side getting close to full mock up, just need to cut the threaded bar to a better length so as not much goes past the nuts.
gapping wise i started with a 90mm gap between block and heads, and am using a 30mm rule- all gaps between castings have to be a multiple of 30mm.

camshafts to head gap is 60mm, rocker cover to head is 150mm.
i tried to keep all gaps 60mm but rocker cover looked to close to cams.
so with the 30mm rule there is actually some symmetry to it when looking at it.

still need to set the cam chain timing but they do turn nice and freely :thumbup:

cheers
Phil
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By h2pmr
#99223
anybody know what the gap is between the block and the lowest point of the throttle body housing?
cheers
Phil
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By worf
#99313
h2pmr wrote: Sat Aug 21, 2021 3:44 am anybody know what the gap is between the block and the lowest point of the throttle body housing?
The thickness of a knock sensor plus the thickness of a M8 hex bolt head plus the thickness of three red hairs…
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By h2pmr
#99328
worf wrote:
h2pmr wrote: Sat Aug 21, 2021 3:44 am anybody know what the gap is between the block and the lowest point of the throttle body housing?
The thickness of a knock sensor plus the thickness of a M8 hex bolt head plus the thickness of three red hairs…
i thought i would need to bolt the throttle housing to the block to give it rigidity, but it took on a life of its own when i made the mounts for the whole intake out of thin mild steel strips, which hold it together more rigidly than i thought

even using the original rubbers and washers that hold the intake to the heads, and original rubbers and washers for the rocker covers

now it is actually coming together quite nicely, just the coolant bridge, water pump, cambelt tensioner and sump to go.

cheers
Phil
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By h2pmr
#99428
nearly there.
yes i know picture quality is crap, will get some better versions when its done.
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By h2pmr
#99448
Thanks Bertrand and a slightly more in focus picture.
so the top end is now done.

next job will be to disassemble it all, cut all excess threaded bar off, get the heads skimmed and send it all to a media blaster's.
then take the block off the engine stand, split it, make spacers for the 2 half's of the block, spacer the sump and make a box section frame to mount it all on.
then disassemble that send all that to the media blasters and see what it looks like when it all comes back.

depending on how it all looks will depend its final finish, all powder coated silver or left natural and just lacquered. but i have a yearning to powder coat the exhaust manifolds red

so will be a few weeks before any real progress.

no good folly's were finished quickly :thumbup:

cheers
Phil
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By h2pmr
#101580
all parts now removed and boxed up to go to the media blasters, this weekend i hope.
block now split and the lower section is resting on the original studs.
i guess these were fitted with loctite from the factory as they don't want to move so will need to take it to work and use some heat on it.
looking at the S2 exploded engine picture they have left all the original studs in and just fitted longer ones and tubes to some of them so i think i will do the same, which also saves fighting to get them all out.

this weekend should be an ideal time to start and fabricate the frame it will be mounted to, should be able to use the holes for the original engine mount position, well thats the plan anyway

cheers
Phil
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By h2pmr
#102753
finally got all the studs out that hold the 2 half's together, Porsche used a lot of locktite when they put them in as needed to heat the alloy with a blow torch and with 2 nuts locked together on the stud they came out.
at least they have steel threaded inserts so no damage to the threads.

i put the outer studs back in just for show and added longer threaded bar to the end journals and nuts and washers to hold it all as a solid unit, just with a 90mm gap between.

40mm box section just resting on block is the start of the frame, one at either end will make it nice and stable, was going to use the original engine mount holes but it just was not going to look right.

as this is the stand the actual sump will be off the ground so just hanging down so can be easily secured with only 4 threaded bars

difficult to see how its going to look from the pictures as its upside down at the moment, but its coming together how i envisaged it, so far....

cheers
Phil
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By h2pmr
#103677
bottom end now finished :thumbup:
just need the legs welding on and a thin brace between them, weld a square plate to the legs and all then ready for the media
blasters.
i had a lot of spare head bolt washers...
still waiting for the top end back from them but no more tube and threaded bar needs cutting :rockon:

cheers
Phil
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