Eric's "Budget" 3.0L Build
 

Okay, my definition of "budget" is that there is one. I don't have deep pockets, but I intend to spend whatever is necessary to build a nice durable street motor.

Greetings, all! My name is Eric, and this is my first thread... I hope it's uneventful.

I'm undertaking an engine swap on a '74 914; the donor engine coming from an '82 911SC. I bought it in the hopes I could do the swap with the motor pretty much as is, but a couple of the cylinders faired rather poorly in the leak down test. So, here we are. It also looks as though it was a bit leaky. Anyway, I've decided to rebuild it, and document the process with this thread. I'm not sure how consistent or entertaining it's going to be, but I'll try.
I'd be grateful if all you experienced engine builders check in once in awhile, cuz I'm going to have questions.

To bring y'all up to speed, I have never rebuilt an engine. I do, however, design them for a living. I've read Wayne's book twice. Bruce's book once. And, I've got a full set of 914/6 factory manuals. The last month was spent tying up some of the 437 projects I currently have going around the house. I've got my work benches cleaned up, my workspace organized, and the engine on it's stand.

Disassembly commenced this past weekend.

I didn't get very far before running into my first issue. Being a couple of years into the camshaft hardware change, I bought Porsche tool P9191 to remove the cam sprockets. Well... my engine has the old style cam hardware. Yes, despite having TWICE read Wayne's book cover to cover, in which he clearly states that the '82 motor he rebuilt for his "101 Projects" book had the old style hardware, I still bought the wrong tool. Hopefully, Pelican will take it back...

The good news is that I've ordered the two correct tools, and tracking alleges they'll both arrive before the long weekend.

Now, I know that nobody will be interested in this if I don't include pictures, so...

The engine as it arrived.
http://forums.pelicanparts.com/uploa...1617133018.jpg

The workspace.
http://forums.pelicanparts.com/uploa...1617132345.jpg

Very sanitary workshop you have there.

Check out our Technical Articles for general 914 info and rebuilding the 911 engine.

Look forward to following the rest of this motor swap.

Good luck on your rebuild. There are lots of very knowledgeable here on the forum. With a name like Detroit can I assume your in the motor city?

David

I'm sure we will be helpful with the return. Let me know if you have any issues. In the meantime, do post lots and lots of pictures of your progress! Do you have one of the 914 so we can see what it'll be going into? Looking forward to following along. :)

Harpo, yes, I'm in the metro Detroit area. Employed by GM...

Luccia, Gianni, thanks for the support. And since you asked for a pic of the car...

http://forums.pelicanparts.com/uploa...1617188426.jpg

Great looking 914 and super looking shop space. I see this going very well.

$5000 tool box. I want one.

Cairo, thanks for the sentiment. I hope you're correct.

pmax, I promise you I didn't spend more than fifteen hundred dollars for that cabinet. It was six or eight years ago that I bought it, so I can't remember exactly... I recall thinking it seemed a good deal, but I still balked at the purchase. In the end I had to do it as I needed the tool storage. Out of curiosity I did a quick search. The same case today is $3200.

Finally, I got some work done on the engine tear down. After welding up and installing the framework for a bar outside my kitchen, something that will see much use in the future, I went about making a cam nut tool. I bought a P202 socket, but Pelican was out of the big assed crows foot. I ordered a big assed socket off of ebay instead. After some time on the lathe, I got a hole bored through for the P202 socket. Then a rummage through the steel laying around for a suitable piece of rod stock. A bit of time with the oxy-acetylene and TIG runner, and voila!...
Honestly, it took frigging ages to do. But I got it done, and it worked a charm.

http://forums.pelicanparts.com/uploa...1617660040.jpg
http://forums.pelicanparts.com/uploa...1617660040.jpg
http://forums.pelicanparts.com/uploa...1617660040.jpg
http://forums.pelicanparts.com/uploa...1617660040.jpg

Nice work but what a hassle. The next time you need a tool that doesn't seem available, you might try posting a request. Many people on the forum are willing to loan a tool or perhaps has a spare to sell. Lot's of DIY guys have tools they won't be using any time soon.
Once again, great effort.

As for the actual tear down, I managed to get the heads off. Everything went smoothly once I had the cam nut tool fabricated. One of the woodruff keys didn't want to come out of its cam, and the cam thrust plates were a little finicky to dig out. There were, however, no broken head studs. I haven't done a thorough inspection of everything yet, but up until now nothing seems overly worn or out of place...

I have to say that opening this thing up has given me a new appreciation for the simplicity of the Chevy small block. All the no-socket-access nuts, shim stacks, funky seals... I'd get laughed out of the design room if I proposed any of that s**t at GM. Yeah, I know that this is a 39 year old motor, but the design was already 16 or so years old. That's pretty mature.

Anyway... Here are a few more pics.

http://forums.pelicanparts.com/uploa...1617661501.jpg
http://forums.pelicanparts.com/uploa...1617661501.jpg
http://forums.pelicanparts.com/uploa...1617661501.jpg

You know, Henry, a local guy offered. I'd already ordered the socket though. People on these forums are great. I asked on the 914 forum if anyone had a spare 901 case I could buy, to use as a mock up in order to get my start cart built. The next day a local guy gave me one... Pretty cool. He's doing a -6 swap on his also, so I hope to get mine done quickly enough for him to use the start cart if he wants... Or someone else.
As they say, what goes around...

Incidentally, Henry, I'd like to talk to you about some of your services. Is there a best time to call?

I start early, usually 6:30 or so and I'm in and out until 5 tues-friday. Earlier is best.
I'm usually answering email and drinking coffee first thing.

So, here's a question for those who know. And I may be getting ahead of myself here, but what is the difference between a Weber 40IDTP and a Weber 40IDA?...

Transition circuits. The IDT is hard to adjust for higher performance engines.
Aaron (BURN-BROS) can probably offer a more exact explanation.

We have both IDTs and IDAs on the self ready for exchange or outright sales.

http://forums.pelicanparts.com/uploa...1617811080.jpg

Belated thanks for the carb info, Henry.

I haven't made a terrific amount of progress (on the engine) in the last week. Removal of the pistons and cylinders is all I managed. The condition of everything continues to appear very good. There was little to no slop between the wrist pins and rods. Nor is there any scoring or scuffing on either the pistons or cylinders. I plan to change the pistons to suit the cams. As for the cylinders, I'm not sure what the correct directive should be. The cross hatching is visible, but the bores are very smooth. At the top of the cylinders, where the pistons reverse direction there are three noticeably polished bands from the rings.

Now for a few questions...

As I understand it, the Nikasil cylinders can be re-honed. Is it fair to assume that this is the correct path?
Can anyone recommend a supplier for the service?
And since we're on the subject of machining/refurbishing services, I'd really like to use local sources if anyone knows of some in the metro Detroit area. I don't mind shipping parts out to the west coast, but it'd be nice to be able to drop things off and chat face to face with the peops doing the work if possible. Plus it sounds as though the usually mentioned suppliers in sunny CA carry pretty long lead times.
Also, do I need to invest in a proper stud removal tool, or is it safe use a couple of nuts and a bit of heat to extract the head studs?

Many thanks.

http://forums.pelicanparts.com/uploa...1618230967.jpg
http://forums.pelicanparts.com/uploa...1618230967.jpg
http://forums.pelicanparts.com/uploa...1618230967.jpg

Don’t hone cylinders, check with dial bore gauge if in spec use soapy water and red scotch brite pad

Dpmulvan, Henry S said the exact same thing in a chat I had with him, but I guess I didn't quite understand what he was telling me. I thought that was just in an effort to clean the bore of carbon build up, etc.
Thanks for the clarification.

This is awesome, and cool to know there's another local Porsche guy, and at GM. Wouldn't happen to work at Design Center?

Can't wait to follow your build, I hope to make headway on mine next year.

Geronimo, I am at the Tech Center - or would be if not for COVID, but not the Design Center. I'm in the Tower...
Life would be a lot easier (and less expensive) if I were not Porsche guy. Or more accurately a Euro trash guy. Unlike this project, I'd have no reservations tearing into a small block. I've done so much design work on that engine I think I could build one blindfolded.
Oh, well... That's what you get with English parents.