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As for the case, Ollie's did great work considering how twisted it was. They had to take 0.035" off to get it back to standard. They did align bore, but couldn't get it back to the minimum size. Quote:
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Bolted on some of the ancillaries...
Got the chain rails installed and a titanium RSR crank pulley from EB Motorsport. I'm a sucker for titanium! http://forums.pelicanparts.com/uploa...1745635999.jpg Updated oil pressure reliefs, oil connection, and sump plate with titanium drain plug from EB Motorsport bolted on with PVD coated titanium M6 socket cap screws and washers... http://forums.pelicanparts.com/uploa...1745635999.jpg Breather cover, oil thermostat, and oil pressure switch. I got a little sloppy with the paint pen, but at least I know they are torqued... http://forums.pelicanparts.com/uploa...1745635999.jpg Question...I'm installing carbs, so is there any good reason to keep these three studs installed? I'm thinking I'll remove these... http://forums.pelicanparts.com/uploa...1745635999.jpg Onward... |
Are the intakes and exhaust ports wide open ? Fab engine!
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Are the ports wide open ?
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Preparing for the next phase of assembly, I moved on to measuring the cylinder to piston clearances, ring gaps, and installing the pistons in the cylinders.
First measured the cylinders... http://forums.pelicanparts.com/uploa...1746322907.jpg Then each of the pistons... http://forums.pelicanparts.com/uploa...1746322907.jpg Per MAHLE's spec sheet, clearance is 0.0254mm to 0.046mm. Did a little mixing and matching to get them as even as possible. All came out within range. http://forums.pelicanparts.com/uploa...1746323058.png Moved on to checking the ring gaps... http://forums.pelicanparts.com/uploa...1746322907.jpg The spec for the top ring is 0.017" and they all started with a gap of about 0.007". About 200 turns on the manual ring file and test fitting 20 times each, got them done. Fortunately, only the top rings needed filing. http://forums.pelicanparts.com/uploa...1746322907.jpg Cleaned and prepped for assembly... http://forums.pelicanparts.com/uploa...1746322907.jpg Rings installed on the piston... http://forums.pelicanparts.com/uploa...1746322907.jpg Insert using a tapered spring compressor... http://forums.pelicanparts.com/uploa...1746322907.jpg Say a prayer, then BINGO! Installed and ready to go... http://forums.pelicanparts.com/uploa...1746324508.jpg Onward... |
Now to check actual deck height...
Back in post #48, I measured the case and other parts and, using a 1mm base shim in my spreadsheet, I calculated the deck height to be 0.79mm (0.031"). Let's see how things look in reality... Started with a 1mm shim supplied by Ollie's... http://forums.pelicanparts.com/uploa...1747279052.jpg Installed the piston and cylinder and found TDC... http://forums.pelicanparts.com/uploa...1747279052.jpg Deck height turned out to be 0.85mm (0.0335"). Pretty close to what I expected... http://forums.pelicanparts.com/uploa...1747279052.jpg When I measured on the opposite side of the piston, I got 0.029". This is a little too close for my comfort. I could stack a 0.25mm and a 1mm shim together to get a better deck height, but this would be about 1.14mm and would lower my compression ratio to 9.98. So doing some googling, I found Hussey Performance who makes custom gaskets in any thickness in 0.001" increments. I gave them a call, sent them one of my shims from Ollie's, and two weeks later got a pack of 6 shims for $150... http://forums.pelicanparts.com/uploa...1747279052.jpg I ordered the shims in a 0.047" thickness, which measured out to be 1.204mm... http://forums.pelicanparts.com/uploa...1747279052.jpg Put everything back together and got a deck height of 0.042" or 1.07mm... http://forums.pelicanparts.com/uploa...1747279052.jpg It took a lot of futzing around, but I think this is a good result. I could have ordered the shims in a 0.046" thickness, but I decided I'd rather err on the side of caution. With this deck height, the calculated compression ratio is 10.06. In case anyone is wondering, I've checked the Harbor Freight caliper against my feeler gauges, and it is surprisingly accurate. Onward... |
Ward and others: FYI, I'm currently running a 103mm forged piston in a motorcycle engine with iron sleeve and .025" clearance and no contact with the head up to 7000 RPM. Per David Vizard, in small block American V8 engines, you can get down to .018" before contact if your pistons don't rock much (e.g., hyper-eutectic cast pistons). The clearances of pistons to aluminum cylinders in Porsche air-cooled engines are pretty tight, therefore they don't rock much either, so I would not be concerned with a .029" piston/head clearance. I have around .030" in my current engine.
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After ruining two rear main seals using the "PVC pipe" technique, I opted for the "proper" P215 tool...
http://forums.pelicanparts.com/uploa...1748731266.jpg http://forums.pelicanparts.com/uploa...1748731266.jpg http://forums.pelicanparts.com/uploa...1748731266.jpg That was much easier! Ready to install the pistons and cylinders. Everything prepped and a little bead of Curil T on the base gaskets... http://forums.pelicanparts.com/uploa...1748733656.jpg Using the Supertec head studs makes attaching them to the connecting rods much easier. However, a word of caution...My casesavers were not perfectly perpendicular to the case, which caused the studs to "porcupine". This became a real nightmare getting a few of the studs screwed into the case. When I do this again, I will install the studs first. http://forums.pelicanparts.com/uploa...1748731941.jpg Seeing that threaded hole in the adapter on the crankshaft gave me an idea...looks like a great place to mount a degree wheel... Bought a degree wheel and positive stop to find TDC... http://forums.pelicanparts.com/uploa...1748732480.jpg Attached the degree wheel to the flywheel side using the RMS tool and made a pointer out of a coat hanger with a little yellow paint on the end. http://forums.pelicanparts.com/uploa...1748732480.jpg I realize that the wheel turns "backwards," but I really just need an accurate TDC for when I get to the cam timing. Cheap and hopefully effective! Onward... |
Ward,
Amazing attention to detail on this build. You asked about the three studs for carbs. I would remove those and plug the holes in the shroud. For the back two holes I just put a nice Bolt and washer in. I used a rubber plug for the 3rd hole where the spacer sits. |
This is my engine. There are many like it, but this one is mine...
I like the look of the 906 cooling tins, so I bought a set from EB Motorsport. When I went to install them, it became obvious that the 906 cylinder is not the same size as my 93mm cylinders from LN. The hole for the spring retainer was about a half inch past the barrel... http://forums.pelicanparts.com/uploa...1748909906.jpg Drew up a modified version in CAD and had SendCutSend laser cut them out of Grade 2 titanium... http://forums.pelicanparts.com/uploa...1748909906.jpg The part as delivered... http://forums.pelicanparts.com/uploa...1748909906.jpg And installed... http://forums.pelicanparts.com/uploa...1748909906.jpg http://forums.pelicanparts.com/uploa...1748909906.jpg Onward... |
Nice
I believe Henry and the guys at Supertek make/sell them . |
Nice
I believe Henry and the guys at Supertek make/sell them . |
It sure is a cool time to live when you have Fusion 360 (and tons of Youtube tutorials) available for free, and then a service like SCS to make custom parts like that for you for a very reasonable price!
Great work as usual! |
Time to install the heads and cam housings...
Heads refurbished, intakes ported, and twin plugged by CGarr... http://forums.pelicanparts.com/uploa...1749005705.jpg Intakes opened up to 37mm... http://forums.pelicanparts.com/uploa...1749005705.jpg Installed on the cylinders... http://forums.pelicanparts.com/uploa...1749005705.jpg Loctite 574 (over) applied to the cam housing... http://forums.pelicanparts.com/uploa...1749005705.jpg And installed... http://forums.pelicanparts.com/uploa...1749005705.jpg Starbase, we have a problem (or two)... |
I ran into a couple of issues.
The first problem was that I'm a doofus... My 15mm 12-point deep socket didn't fit through the cam housing, preventing me from getting to the head stud nuts to torque them down. Figuring that a semi-deep socket would work, I bought a Snap-on socket off ebay. When it arrived, I could get past the housing and down into the hole. At this point I realized that the nut was 14mm and my deep socket that I already had would fit great. Not a big deal, really. I'm just out $50 for a socket that I'll probably never use. Anyone need a Snap-on 15mm 12-point semi-deep socket? I'll make you a deal... http://forums.pelicanparts.com/uploa...1750029684.jpg My second problem was a little more serious. When torquing down the cam housing to the heads, this nut wouldn't tighten past 15NM... http://forums.pelicanparts.com/uploa...1750031134.jpg The only way to assess the situation and repair the damage was to tear everything apart... http://forums.pelicanparts.com/uploa...1750029684.jpg http://forums.pelicanparts.com/uploa...1750029684.jpg Threads on the stud basically disintegrated... http://forums.pelicanparts.com/uploa...1750029684.jpg Removed all the Loctite 574 and replaced the stud with an extra one I had in my stash... http://forums.pelicanparts.com/uploa...1750029684.jpg All back together... http://forums.pelicanparts.com/uploa...1750029684.jpg Onward... |
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Nice build. Were the deck heights on each cylinder the same?
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This is a very nice build! Also all the photos and info are great as I will be rebuilding my engine soon too. Thanks!
What oil pump did you use btw? |
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I see you have those vertical marks in your barrels... |
Time to prep the chain housings for installation.
Apply Dykem... http://forums.pelicanparts.com/uploa...1750460076.jpg http://forums.pelicanparts.com/uploa...1750460076.jpg Sanded flat... http://forums.pelicanparts.com/uploa...1750460076.jpg http://forums.pelicanparts.com/uploa...1750460076.jpg Apply Loctite EA 9340 epoxy... http://forums.pelicanparts.com/uploa...1750460076.jpg Found a "worm hole" in the magnesium... http://forums.pelicanparts.com/uploa...1750460076.jpg Not the best picture, but filled it up with the Loctite EA 9340 epoxy and sanded smooth... http://forums.pelicanparts.com/uploa...1750460076.jpg Onward... |
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