Is an engine rebuild possible for a complete novice mechanic?

[chrismorse]

A few more thoughts:
It is very helpful to have a big enough space to spread things out. Similarly, you can't have cats jumping up on the bench, or kids moving bikes in and around your project. You need enough room to organize, clean and store parts and tools - this makes it a lot less stressfull, (I've got three cats and keeping them out of the work area is a constant challenge).

Maybe read up on the project and do the engine removal and ship the long block to a shop, while you work on all the less technical stuff that still costs a lot: cleaning and painting, overhauling the alternator and starter, replacing fuel lines, buying and installing all of the bits and pieces, ( oil pressure sending unit, clutch, pilot bearing, cleaning the engine compartment, fuel filter, ignition system, oil tank and lines and on and on.
You can research and undertake many small bits of the big job and this will save you a lot of money and get to know the car better, while leaving the highly skilled, critical work to a trusted shop.

I was once a service manager at a dealership, (not Porsche) and i have a lot of respect for the guys that really do the job. I would recommend becoming more familiar with wrenching on the car before diving into the deep end.

It is a big task to set up the shop space/ storage, assemble all the tools, find help on a timely basis, pull together the money, Make sure your wife doesn't become a porsche widow.

Maybe, take it in smaller bites.

Good luck,
chris

[doswald]

To echo Chris’ point-I helped a friend rebuild his MGB motor in his carport in the mid-70s. We had everything neatly organized in paper cups…until his dog ran through the carport grabbing cups in his mouth and scattering the contents across the back yard!

dho

[hcoles]

One thing that helped me with keeping the stress low during the process is putting parts that go together as a unit along with the fasteners that connect the parts to other parts all in one box. Then 3 or 4 months later it helped... I get to a point and open a box and all the stuff needed was in one place. This also seemed to keep things from getting lost. I probably had a stack of 10 or more boxes.

[MichaelSJackson]

Photos, photos, photos. Before you take anything apart, take multiple photos, from different angles. These types of projects take longer than my memory can persist. So photos are a cheap time/angst saver.

[930rsr]

Years ago I rebuilt my 1976 930 Porsche motor. While it was not the first motor I'd rebuilt, it was the first Porsche motor for me, and it was by far the most complex and time consuming motor I'd ever built. The engine build went great, but it took me months to assemble it. I did most of the work on weekends and some of the machine shop work was very slow.

I consider myself experienced when it comes to working on cars and even with my experience I attended The Bruce Anderson and Jerry Woods engine rebuilding class, and observed Jerry rebuild a motor from beginning to end in front of the class. The in-class lesson was very valuable. There is so much that goes into building a Porsche motor and some special tools will make the job a lot easier.

While I won't say you can't be successful building a Porsche motor as your first motor, I will say, if you make an mistake in your build, it can potentially be a very, very expensive lesson. My personal recommendation is to leave this job to an experience mechanic, or find a member in the club who's successfully built an engine or two and solicit his or her help/support.

Please watch a video of a complete engine build, and I think you will come to the same conclusion. This is not a simple undertaking. There are lots of measurements that need to be done and some areas where parts replacements or rebuild are judgement calls where experience is the best teacher. This is just my two cents.

[sch2046]

The class in April will be on engine rebuilding? How would I sign up and what is the date?
Thanks
Sean

Originally Posted by boyt911sc

The answer to your question is NO. If you have the desire and interest to learn to rebuild your 911, you could do it. I have disassembled and assembled a 911 motor more than a hundred times and I am not even a professional mechanic. Just an avid DIYer like anyone in this forum.

My advice to you at this point is to over-come your fear and anxiety about 911 motors. It is one of the easiest motor in the planet to work. Many would disagree but I find it fun and enjoyable to rebuild one. Learn how to drop the motor/transmission and you will be on your way to engine rebuilding. Majority of the participants who attended the Engine Rebuilding Workshops in April 2018 and September 2021 had not done an engine drop before but eager to learn rebuild a motor. Some of them have successfully rebuilt their motors.

I will be back home in 2 weeks and will start another 911 teardown very soon. You are welcome to observe and see first hand how it is done. There are more than 2 dozen people failed to attend the last workshop in September due to Covid-19. To deliver my commitments to them, I am planning another workshop in April 2022 and finally retire doing it.

Tony

[boyt911sc]

Originally Posted by sch2046

The class in April will be on engine rebuilding? How would I sign up and what is the date?
Thanks
Sean

Go search posts by ”Boyt911sc” and find the “Introduction to Engine Rebuilding” thread. Go to the last page and find the dates you could attend. PM your full name and email address to me. I will add your name in the list. Thanks.

Tony

[breakerbar]

From a newbie in the middle of his first rebuild, a 3.0L from an 82 SC:

Although I have never rebuilt any engine, I have spent a lot of time under the hood with a wrench and have a good understanding of engines in general. Further, I have never been too intimidated to try to do anything myself. Also, I have a serious need for information and control. And maybe I have a bit of perfectionism too Whether these are prerequisites are not, I don't know, but they influenced my decision to do it myself, for sure.

I did talk to a couple of shops and was not satisfied with anything I heard. The cost was high of course, but I think I just didn't have the confidence that my standards would be met. I didn't go into this as a cost saving exercise, anyway. In fact, I have budgeted basically the same amount, in effect giving myself the ability to address anything and everything I find 'while I'm in there.'

All that being said, I'm really enjoying the rebuild process. It can sometimes be stressful, but I would make the decision to do it again. In fact, I find myself thinking about what the next rebuild will be when I am finished with this one. So many great cars out there and all these new tools

[rog540]

Originally Posted by boyt911sc

The answer to your question is NO. If you have the desire and interest to learn to rebuild your 911, you could do it. I have disassembled and assembled a 911 motor more than a hundred times and I am not even a professional mechanic. Just an avid DIYer like anyone in this forum.

My advice to you at this point is to over-come your fear and anxiety about 911 motors. It is one of the easiest motor in the planet to work. Many would disagree but I find it fun and enjoyable to rebuild one. Learn how to drop the motor/transmission and you will be on your way to engine rebuilding. Majority of the participants who attended the Engine Rebuilding Workshops in April 2018 and September 2021 had not done an engine drop before but eager to learn rebuild a motor. Some of them have successfully rebuilt their motors.

I will be back home in 2 weeks and will start another 911 teardown very soon. You are welcome to observe and see first hand how it is done. There are more than 2 dozen people failed to attend the last workshop in September due to Covid-19. To deliver my commitments to them, I am planning another workshop in April 2022 and finally retire doing it.

Tony

Educative… great topic

[roy gray]

Stupid question-why does it need a rebuild?Does it spin over?Is there a crack in the block?Does it run like S**T?Does it run but make loud banging noises?If your car was at my shop,in this order,I would be going over your 911,or Geo Metro with these same questions.To answer your question regarding you rebuilding it.No,you shouldn't try.The reason I advise this is because your own words explain that you not only don't have the experience,but more importantly the confidence.These are complicated motors compared to a smallblock pushrod Chevy v8.A VW pushrod motor is requisite training for Porsche flat 6's.But to try this with NO motor rebuild experience is pointless.BTW,your rebuild shouldn't cost 25k either.A lot of the guys who stake their reputations on building these motors want you to think they're performing magic.They're not.Feel free to text or email me.phone:2066192319.email:rg3po@comcast.net.Any questions,anytime.I only go tp Pelican forums maybe twice a year,but I buy parts from them more often.Cheers,Roy

[Rosco_NZ]

Some real world experience … the books & videos available are great. But really more like an assembly guide than detailed instructions. At first hurdle, installed IMS shaft and too little thrust clearance and minimal gear backlash. No one has vids on how to deal with this .. this is where things get tricky as solutions must be found and old school builders know how to ‘build’ not ‘assemble’ an engine.

Having said that, if you’re mechanically technical, practical, extremely patient and like a challenge, yes there are good resources to help you.

Hotspots:
Inserting piston pin clips
Checking deck height
Setting Cam Timing
Check piston to valve clearance

[bpu699]

I’m getting ready to put my 930 motor back in, hopefully next weekend. It’s been 3-4 years since I started. Like many life got in the way, and frankly lost interest. I suspect there’s dozens of folks on here with half completed motors.

I like to think I have every tool known to man, lathes, micrometers, etc. even working on cars for 30 years.

This was my first complete rebuild. I would not recommend this for a novice.

It’s involved, finicky, and if you screw up you need to split the case… which is essentially an entire redo.

[Geronimo]

As many have suggested, get and read the books mentioned. Also Tony's class is a MUST, Tony is amazing and will give you insight into the little details with real hands on experience. You will get to know your fellow Pelicans, and have a great time.

I would gladly take the class a second time it's that good.

Work out a plan on paper, all the parts, all the details, all the costs! Source the shops you plan to have do the work you can't like cylinders coating and head rebuilding, and machine shops.

You might get some insight into the go to shops from the class as well.