I managed to get Nylon filament to print reliably. These parts should be much stronger than PLA/ABS and also much more heat resistant. I used Taulman 618 filament and Garolite G10 print platform. Here are some pics of the process.
I had a little downtime waiting on parts, so I decided to do something fun with the interior. At first I was going to paint the dash black, but the red kind of grew on me, so I decided to keep it. The doors cards on the other hand had to go! The faded salmon carpet look is not very appealing.
I got the idea from the new door cards from the classic Porsche 911 RS. The fabrication was a bit of a pain in the butt due to 3D shaped door frame, but I think it turned out ok. In the future I might upgrade the top trim to something a little firmer. I currently have mattress foam in there, but I think pink insulation foam might be a little more fitting.
After lapping the valves, I did another leak-down test. The results were much better this time, but still pretty inconsistent. The worst cylinder had 25% leakage and the best 7%. I put a little engine oil in the cylinders to see if it would seal a little better, but I noticed no improvement. You could clearly hear the air passing through the piston rings. Since my build is on the budget, I decided not to continue with the cylinder job. The scrap yard was nice enough to take the engine back and give me a full refund. It was a little disappointing as I spent quite a bit of time on it.
For the next engine I decided to spend a little more and get an L33 aluminum block. These came with 799 heads, which are pretty much the same as the ones that came on LS6 Corvette engine, minus the sodium filled valves. It was a little overpriced at $1200 CAD, but I couldnt afford to sit around waiting for a good deal. The engine looked pretty clean, and only had 80,000 miles.