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.

lol, I have 3 broken head studs and a desire for much more power. Life would so much easier if I had a Vette... But alas I have a love of the fancy beetles.

Right!... But then I'd have to trade my Ducatis for a Harley.

See you guys at Dream Cruise in August! :)

I like the vibe of this thread. Following.

Stanglife, I live a stone's throw from Woodie, so the Dream Cruise is honestly more an inconvenience than anything else! That said I love and unequivocally support it. For all of you out there that have never experienced it, the Woodward Ave Dream Cruise is a true spectacle. It's not really a Eurotrash type of event, but that's not to say sports cars don't have a presence. I've seen just about everything. Gullwings, Ferraris, Lamborghinis... You name it. But it is truly the domain of muscle cars and cruisers. I don't know how many cars actually show up, but it's basically a car show that goes on for ten (or more) miles. At the north end they run drag races. And I don't mean 90's mustangs and the like. They've had honest to god top fuelers running down Woodward. The start line is literally about fifteen feet from an active railroad crossing. The finish line is effectively the McDonald's and gas station at the corner... That's not something you see at your average cars and coffee.

Mikedsilva, I appreciate the sentiment. I just wish the guy who started the thread would move it along a little!...
I hope to make some progress this weekend. That being pulling the head studs, and splitting the case. We'll see though. Apparently, I've been dating my girlfriend for two years this weekend. That fact may limit my garage time.

We come up from Florida every year. I brought a car friend of mine last year and he loved it...his wife isn't a car person and she called it "watching traffic" lol. Debbie Downer!

We always stay in Ferndale but end up parking around Royal Oak and walking to Birmingham. You really do see a little of everything. I was into Audi at one point so my wife pointed out the "Audi lot" where there were about 5 cars, haha. Mostly domestic there.

Favorite car of all time? Camrino. Someone turned a Toyota Camry into an El Camino and had the plate, Camrino haha..
https://www.instagram.com/p/BX8kZaKgE1P/

Unsurprisingly, I did not get as much done this weekend as I'd have liked. This balancing hobbies and relationship thing is tricky...
Anyway, I got all the head studs removed with no real drama. A few of those blighters did not want to let go, but they all eventually yielded. And none broke.

I did attempt to get the the crank balancer bolt out, but that thing ain't moving. My impact wrench and 160psi would not get it turning. Any input from y'all on the subject? Could a crank stop on the flywheel and an enormous breaker bar damage the crankshaft? I would think not, but better asking the question now than searching the want ads for a crankshaft later...

Here's a pic of the engine in its current state. I know; it looks pretty much looks the same as the last pictures, but I did warn that I work slow... And I have at least been spending some time cleaning parts and whatnot.
http://forums.pelicanparts.com/uploa...1619444221.jpg

I did also pick up a set of Webers a couple of weeks back! Disappointingly, I'm going to have to rebuild them to some degree. Sold "rebuilt as new", the vender didn't bother to re-plate some of the smaller bits. You get what you pay for.http://forums.pelicanparts.com/uploa...1619444470.jpg

Well, it's taken awhile, but I've finally got the case split. The crank journals all look about as perfect as I could hope. As do the crank and intermediate shaft gears. So, I'm pretty chuffed about that... I hope to get a couple of solid days on the job this weekend as the girlie is going out of town. Fingers crossed, by the end of the weekend I'll have the whole thing disassembled, and the various bits and bobs ready to ship out for refurbishment.

http://forums.pelicanparts.com/uploa...1620130823.jpg

http://forums.pelicanparts.com/uploa...1620130823.jpg

I admire your initiative! What a great project.

Wow, those journals look great.

following your build!

Eric, nice project you have going here . Have you thought about the camshaft that you are going to use ? I'll post a link here from Pelican , https://forums.pelicanparts.com/porsche-911-technical-forum/1073886-3-0-rebuild-performance-advice.html
From post 10 and on there is a lot of info on CIS cam and power .
Keep at it , and you will love where you end up.
Ian

Well, it's been a few weeks since my last post. They say if you want to get something done, ask a busy person. I'm sure as hell busy, but still struggle to find time to work on this engine... I have, however managed to get the head assemblies disassembled. I've also got some bits and pieces like the intake manifolds stripped of studs, etc. and ready for ceramic/powder coating. Not to mention some fence posts dug in, a bar built and installed outside my kitchen, and various other house projects...

So, I guess I've now just about reached the point where I'll be sending the various components out for cleaning, refurbishment, plating, powder coating, and the like. I've started on a spread sheet to keep track of everything, because... there's a lot of stuff.

That said, I'd be grateful for any supplier recommendations. Ideally, I'd like to deal with suppliers local to the Detroit area, but I'm not averse to shipping. And by suppliers, I mean for everything. Parts cleaning, ceramic coating, crankshaft magnaflux/polishing... You get the idea. Please, don't hold back.

http://forums.pelicanparts.com/uploa...1621429948.jpg

http://forums.pelicanparts.com/uploa...1621429948.jpg

http://forums.pelicanparts.com/uploa...1621429948.jpg

icarp,
I don't know yet what I'm doing for a cam grind, apart from NOT using my current CIS grind. I'm ditching the injection in lieu of Webers, and intend to take advantage of that. This will primarily be a street car, with hopefully the occasional track day, so it's got to be tractable. And lets face it, a 914 only weighs a bit over two thousand pounds. It'll be plenty entertaining even without a race motor.

So, I guess I'm open for suggestions. Especially from those who've walked this path before.

Also, am I best off having my current cams reground, or buying new ones and selling these? I'm guessing the former, but it's worth asking the question. These appear to be in excellent condition with the exception of one lobe (see image).

http://forums.pelicanparts.com/uploa...1621430666.jpg

http://forums.pelicanparts.com/uploa...1621430666.jpg

Craig Garr is in Grand Rapids. His user name is Cgarr. Does great work.

Cams... I would go with a DC40 (ModS) cam. Not sure if these can still be ground on SC cores or if you have to get new billets. Plenty of torque for your light car. Plenty of high rpm zing. Not all high rpm where you need significant oil modes. If you go with more cam the weber (40mm?) may not be large enough to support the airflow.

If you want to regrind the cams... Talk to any of the cam builders to see what is the most profile you can put on them. That one lobe has pitting. This will need to be repaired/welded or the cams replaced.

Pistons. Looks like you have Nikasil cylinders. A set of JE/CP or other pistons with larger valve pockets would be required for the cam listed above. Step to 9.5:1 Compression while you are in there.

Crank. I would cross-drill the center mains to improve oil feed to 2-5 rod bearings. This is pretty standard on a performance build.

Case. The 3.0 case should not need any machine work but should complete the usual cleaning and measuring.

Heads. The 82 SC has the smaller port heads. Open them up to 38mm for more airflow. I would port the manifolds to 37mm. The slight step (lip) will help with anti-reversion to the carbs.

JP,
Thanks for the input. I have heard of Craig before, but have yet to contact him. My brother is in GR, so he'd work out well.
I am indeed using Weber 40's, and do plan to bump the comp ratio to 9.5:1. I had a nice long chat with Henry Schmidt several weeks back, and that is exactly what he suggested also.
I had not heard the crank could use cross drilling, so I appreciate that little tidbit.
And I was hoping to hear that additional case machining should be unnecessary.

Awe man another Metro Detroiter, I would love to "observe" the assembly of the engine as prep for when I need to fix mine.

Good thread here. Keep us informed on your upcoming suppliers and details. I have a 912E-3.0 someone else swapped a dozen yrs ago, and (sorta) look forward to hot rodding the power plant similar to your plans except for a desire for EFI TBI. Good job and beautiful 914.

Geronimo, it's going to be some time before I'm putting this thing back together, but when that time comes a second set of hands will likely be damned useful. Get a hold of me...