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Turning Lemons into Twin Plugs
Won't bore everyone with all the details leading up to the lemons. Suffice to say I had a basket of lemons drop into my lap on a sunny June day while cruising my 911ST tribute.
While waiting for the tow truck I went through the Kubler Ross five stage of grief: denial -- that ticking noise is nothing bad anger -- that ticking noise is something bad bargaining -- it will be an easy fix depression -- it will not be an easy fix acceptance -- I can get twin plugs! This thread is dedicated to several people for different reasons. Over the years working with many people, for different reasons, in many fields; I've learned to keep my expectations 'low' for fear of disappointment. Maybe I'm cynical. Maybe I expect too much. So when I meet and work with people who exceed my expectations, it's not only refreshing......but I feel an obligation to 'pay it forward'. Not for the people that helped me but for the people that need the help....people like me. "Dan on 94". This was a complete stranger to me at the time who is a porsche-phile. He saw my car in distress and pulled over to help. Who pulls over on a Saturday afternoon to help a stranger? In Chicago? On 94? Who does that anymore? He helped me troubleshoot the problem and gave me the name of someone who might be able to help..... Tim Olsen of Olsen Motorsports in Chicago area Downers Grove. There are few people I've met and worked with that are the 'real deal'......he and his team are it. Tim and his team have turned this basket of lemons into twin plug lemonade. Will also be thanking Marc Zurlinden who was original architect of the build......Smyrna. Not only did he put together a great project he stood behind it. Another rare thing in today's world. I wanted to post up the pictures of the process as I've enjoyed that myself. This forum has been such source of help and great information that I felt I needed to share hoping that someone can learn from this somehow or benefit in the future. Hope you enjoy. http://forums.pelicanparts.com/uploa...1545966105.jpg |
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Is this normal??? No. Spun bearing unfortunately. Caught relatively early so damage could have been worse. This needs complete takedown of everything including oil lines, oil cooler, oil tank, oil galleys, etc.......essentially starting with blank slate.
http://forums.pelicanparts.com/uploa...1545966610.jpg http://forums.pelicanparts.com/uploa...1545966610.jpg http://forums.pelicanparts.com/uploa...1545966610.jpg |
Subscribed...
Did the bearing break apart? Sent from my iPhone using Tapatalk |
Starting the restoration........powdercoating tin, cadmium replating, etc
http://forums.pelicanparts.com/uploa...1545967108.jpg http://forums.pelicanparts.com/uploa...1545967108.jpg http://forums.pelicanparts.com/uploa...1545967108.jpg http://forums.pelicanparts.com/uploa...1545967108.jpg http://forums.pelicanparts.com/uploa...1545967108.jpg |
Starting to make lemonade.......might as well do some nice colors.
http://forums.pelicanparts.com/uploa...1545967249.jpg http://forums.pelicanparts.com/uploa...1545967249.jpg http://forums.pelicanparts.com/uploa...1545967249.jpg http://forums.pelicanparts.com/uploa...1545967249.jpg |
Crank was in good shape. This is original crank from 1987 carrera 3.2. Had some custom knife-edging done to decrease some weight. Had rod journals reground and everything ion nitrided and polished.
http://forums.pelicanparts.com/uploa...1545967892.jpg http://forums.pelicanparts.com/uploa...1545967892.jpg |
Rod bolts being measured for 'stretch' and bearing clearances being checked.
http://forums.pelicanparts.com/uploa...1545968023.jpg http://forums.pelicanparts.com/uploa...1545968023.jpg |
Oil pump is from 964. Nice upgrade for these engines without having to do any case work.
http://forums.pelicanparts.com/uploa...1545968158.jpg |
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Measuring for 'volume' and figuring out true compression. Originally this was a 3.2 engine that was rebuilt to 3.4 using 930 cylinders. Pistons are JE 'wedge dome' design for 9.8:1 CR. This was originally single plug. Figured 'while we are in there' to convert to twin plug.
Cylinder heads are being filled to measure volume....... 89 cc for each one. The piston, head, and cylinder then reassembled and volume measured again at TDC and BDC to get true CR.......9.8! I may have been able to go up on the CR especially with the twin plugs but didn't feel the need. Reliable > performance here. http://forums.pelicanparts.com/uploa...1545968528.jpg http://forums.pelicanparts.com/uploa...1545968528.jpg http://forums.pelicanparts.com/uploa...1545968528.jpg |
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Symptoms started as 'ticking'. Almost like vibrating sheet metal that is loose. Then ticking gets louder. Then power starts to cut out. Then you call a tow truck. |
Did you determine a cause for the bearing failure ? Always something to learn here.
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Curious as to why you wanted to go twin plugging if the compression is staying at 9.8.. was it "just in case" the true compression worked out a bit higher?
Those photos are brilliant. Possible the best photos I have seen for an engine rebuild; very impressed! |
Unable to determine cause of failure for certain. Some theories. It was number 4 rod bearing. It was not oil starvation, bad oil, etc.
Engine was almost new. Engine was originally built by reputable builder (Not Marc Zurlinden but someone he utilized). Wish there was more to learn to avoid in future. |
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Should also add some reliability and added insurance if bad gas used. Seemed like a 'small' price to pay given circumstances. Originally the engine was single plug. Photos are from Tim Olsen so he gets credit. This is part of why he's been great to work with......he is great communicator with phone, text, pictures. He uploads pictures to a shared site every time he works on it. This has made the process 'fun'. |
Beautiful work. Make sure he turns that head around 180 degrees!
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breaking down on the Dan Ryan is the kind of thing nightmares are made of....let alone in a 911.
glad it's working out even if that lemonade is expensive. |
Very glad you came to acceptance early on! Wonder what kind of rod bearing clearances were there initially, and what type of oil? Did any of the other rods look like they were about to go bye bye?
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Whoever built the engine into a 3.3 used FAR too much #574 and that may have contributed to the bearing failure.
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-what makes you think excessive #574? Not questioning your expertise, I'm still a rookie and am also in the middle of rebuild, not trying to high-jack, I think may people would like to hear details from you thanks +1 for the excellent photography on this post also |
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The wedge shaped Max Moritz style piston were specifically designed for single plug.
Is it not easy and relatively cheap to get new pistons with higher compression and correct domes to accommodate your new twin plug? |
I think the amount of 574 on the case halves.
Without data other than the excess 574 on the threads, there may have been other locations with similar excess that broke loose. Did you have a picture of the other side of the case? Maybe that had more evidence of excessive squeeze out on the inside. Oil is not air, so wet 574 should cure. 574 also cures with time and heat it seems on my outside cam cover edges. |
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You are correct that they are designed for single plug but dual plug will still have added benefits from what I understand. Does anyone think that the wedge-dome design somehow will be 'bad' with the dual plug setup?? |
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Here are other pictures of the case. http://forums.pelicanparts.com/uploa...1546126323.jpg http://forums.pelicanparts.com/uploa...1546126323.jpg http://forums.pelicanparts.com/uploa...1546126323.jpg |
Things are starting to go back together..........
http://forums.pelicanparts.com/uploa...1546127490.jpg http://forums.pelicanparts.com/uploa...1546127490.jpg http://forums.pelicanparts.com/uploa...1546127490.jpg |
Here's the crank/rods in place ...........
http://forums.pelicanparts.com/uploa...1546127708.jpg http://forums.pelicanparts.com/uploa...1546127708.jpg |
Cylinders and jugs coming together........piston rings getting hand lapped like the rails on my 1911 LOL......
http://forums.pelicanparts.com/uploa...1546127804.jpg http://forums.pelicanparts.com/uploa...1546127804.jpg http://forums.pelicanparts.com/uploa...1546127804.jpg http://forums.pelicanparts.com/uploa...1546127804.jpg http://forums.pelicanparts.com/uploa...1546127804.jpg |
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Pics documenting Tim's level of OCD.......brushing away excess sealant......
http://forums.pelicanparts.com/uploa...1546128891.jpg http://forums.pelicanparts.com/uploa...1546128891.jpg http://forums.pelicanparts.com/uploa...1546128891.jpg |
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This is so fun to see. Engine parts being assembled.
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Pretty nice rack there sir.
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Love the look of all the metal parts. Were they all vapor blasted? If not, how did they get that clean?
Thanks, Rick |
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Looking good there gwag. Very nice. Every time I see one of these threads, it has me re-thinking building the 3.0 in the corner of my garage, but I think I've spoiled myself with displacement. :confused: I built a 3.6 for my 81', and it's a powerhouse. I built a euro 3.3 turbo before that, and was blown away by the power it delivered. For those out there who have been down this road: will a 3.0, modded to 3.2SS with good injection, come close to the power from either of the above mentioned two? I'm thinking I've spoiled myself, and need to give-up on the idea of building a 3.2ss, and search for another 3.6.
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