3.0-3.2ss re bild for new DIYer - Am I crazy?
 

Hi everyone

I am not asking here about how to do this, I have read a lot of other posts here about this. I am asking can this be done by a novice DIYer who has so far had success at smaller tasks or should I buy the peace of mind that comes with taking it to a reputable builder?

Here's my situation:

1979 SC 3.0 I have owned for 2 years. For anyone who follows me on instagram (@79.outlaw) you will be familiar with what I have done so far which is:

Installed JWest Short shift kit & Precisions Shift Coupler, installed front strut brace, pedal boards and pedals, string wheel hub, quick release and new wheel. Removed CIS to address all the usual suspects for oil leaks, pulled original heat exchangers, vapour blasted and repainted, swapped CAT for M&K Active Exhaust bypass, replaced fuel lines from tunnel to engine bay and all CIS lines, new breather hoses, removed and repainted engine shroud, cleaned top and bottom of engine (all done engine in), pulled fan housing, had alternator rebuilt, fan housing and fan vapour blasted, new alternator strap, new plugs and wires, dizzy cap & rotor, new fuel pump, new coil, new engine oil cooler.

My mechanic has rebuilt suspension front and rear, swapped brakes and rotors for Carrera.

Today I pulled the valve covers for the first time and found 2 (yes 2!) missing head studs, 1 each on cylinders 1 and 3. So time for a rebuild.

I am getting quotes but they are all coming in at over $25k (CND - I am in Toronto). I cannot afford this. The car has run wonderfully for the 2 years I have had it and who knows how long it was driving like this before? My hope is that I can enjoy her for the summer and look to rebuild when the Canadian winter season hits in November. I don't track the car and I don't drive her hard (yet).

I am confident, I read everything three times, I ask a lot of questions and am very aware of my own limits.

CAN I DO THIS MYSELF?

With time, patience and a thirst for knowledge could I in reality rebuild my engine and take it from a 3.0 to a 3.2 short stroke alone, sending anything out for machining that I needed to?

This is not about taking work away from anyone who builds engines. Those of you here who can do this will relate to what I say next. The pride of driving my 79 with an engine I have rebuilt myself would be a dream come true.

So.... Am I nuts to consider this? Is it too much for someone who has never done this before to take on?

I need advice (or reco's for a reputable builder who won't rape me on pricing)

As always - thank you in advance for any advice you are willing to give!!!

Dan


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rebuild
 

sounds like you have the right mind set . Start out with the disassembly and take it from there . Locate a local machine shop and maybe they can also recommend a local porsche mechanic that may be interested with helping you reassemble . Cam timing , sprocket alignment and piston install are all a bit involved the first time around but you can do this and save a ton of money . Take your time and read a lot . Tons of information online . If you lived close to NJ Id be happy to help . Good Luck and Enjoy the process...

25k... numbers like that were all the motivation I needed to do my 3.2 top end + myself. Im now doing the same and a lot more on my 964. Both projects cost me a laughable fraction of what I would have paid someone and allowed purchase of excellent tools, onboarding of deep knowledge and great satisfaction. You can do it. Do it.

Yes you can do it

My first ever rebuild was my 3.0.

You can totally do it. Take your time, find a great machine shop to do what's compulsory, and enjoy the process. You will learn a ton about your motor, acquire some skills, and take great satisfaction in knowing you had the courage to commit yourself to this.

Yes, you can do it. Remember that if in doubt, take your time, double check, and consult the factory manuals where applicable. They are great. Never apply more force than you know is required. If you don’t know torque specs, etc. just wait until you find them. Make sure you are insanely organized during disassembly and assembly. Some things take feeling which you won’t have from the get go, like installing pistons in cylinders - bring a friend along who’s done it before. Make a checklist of all parts during disassembly so you don’t forget anything when putting back together.

Totally do-able. Is Jay Lloyd's Klassix still open up by you? I know Jay had some health issues and sold his 934 tribute, but he'd be a great asset if you ran into trouble during your build.

Try call Franzi at Auto Select in Toronto, he is an absolute air cooled guru and a wonderful human being!

yes you are crazy. Stay well away and concentrate on making minimum damage. Do not open engine block and do not touch cylinder heads unless it cant't be avoided. Based on my own mistakes I recommend just replacing lower studs and be done. Don't even change piston rings. This is what I should have done, but instead I thought I knew better and ended up spending an absolute fortune on nothing.

How much do you estimate the cost of rebuilding yourself?

Hey! Yes, Jay is incredible and my mechanic. No one else has touched my car. He rebuilt the suspension and brakes and did a fantastic job. I have actually already spoken to Jay to see if he would be open to helping me but it's sadly not something he's into which I completely understand and totally respect. Its hard because this is something I really want to do myself but I would love to do under the supervision of an expert and this is also something I am very willing to pay for. It's not at all the cost I am trying to avoid. It is the pride of having done it myself. But I also completely appreciate that in asking a craftsman like Jay for help is circumnavigating his profession and how he earns his living.

It's catch 22 and sadly Jay is unable to help but he's an incredible man and I have a tremendous amount of time for him!

Thanks!! Good to know, I will definitely reach out.

I am planning a top-end only if I stay with CIS then I would hope for $7k and be prepared for $12k.
If I switch to PMOs I will hope for $10k but be prepared for $15k.
Duane Wik is currently playing with a new setup using individual throttle bodies from a GSXR which looks really interesting. His setup is cost significantly less so I am going to be watching his build very closely to see how it goes which could costs way down.

Never building an aircooled motor before, I opted to hang the CIS back on the car because I wanted to minimize the amount of variables and get the car on the road quicker. The 3.2ss with 9.5:1 JEs and 964 cams has plenty of snot, and with the CIS dialed in the car starts, idles and runs like any modern car. My plan was to do ITBs but early (78-79) CIS is dead simple and awesome so I used the money to build a bulletproof 915 instead.

Like baking a cake. Just follow the instructions, be careful, ask questions of the group here and other places. It's not that hard. Really only goes together one way. You are really just doing the disassembly and reassembly. Everything else is either from the machine shop or new parts.

Chris
73 E
89 Carrera