My 3.2 Build

[irobertson]

I figured I would start a thread about the overall build instead of starting a new thread every time I have a question.
Yesterday I bolted the case halves together and measured the main bearings with my bore gauge. Clearances came out to be between 0.0027 and 0.0033.
With the outside end of the spec being 0.0028, it looks like I will be a tad loose on a couple of the mains with the worst being a half thou over.
I also installed the rods on the crank.
The rod clearances are between 0.0032 and 0.0035, so within spec.

So, question #2
Regarding the 3 Mains studs. I'm thinking they should be left a half turn from bottoming out in the case to allow to the difference in expansion coefficients of the two metals. Is that correct? Or should I snug them right to the bottom?

And lastly, a pic from yesterday's fun.

[ozracer]

How did you get the case so clean it looks beautiful did you bead blast and tumble clean?

[irobertson]

Originally Posted by ozracer

How did you get the case so clean it looks beautiful did you bead blast and tumble clean?

I masked off the machined surfaces and all the openings into the oiling system, then bead blasted it.
Although I was happy with the results, I have to admit, it was a really bad idea. Even though I masked things really well, glass bead got into places it shouldn't have.
I ended up having the oil galley plugs and piston squirters pulled so that things could be cleaned out properly. On the plus side, I do have 6 new piston squirters.

[ozracer]

Are the piston squirters expensive it really looks like brand new though

[500_19B]

Hello Ian,

Any studs I installed a left a half turn or so of end clearance and let the Loctite do the work.

The case looks beautiful, but you were right to take the plugs out. I have heard a lot of horror stories from errant grit left somewhere. Even from one very reputable shop that allegedly took all sorts of care and still ended up with issues, so one can't be too careful in the clean up effort!

I just stayed with carb cleaner and pressurized water. It does not look as good, but I think it was functionally clean.

[KTL]

Originally Posted by ozracer

Are the piston squirters expensive it really looks like brand new though

Not really that expensive

New Page 1

[sjf911]

Which main bearings are you using? I had a similar issue with Glyco replacements and finally had to go with Porsche mains sourced from the dealer.

[TT Oversteer]

Soda blasting is a great way to clean cases and aluminum castings where you need a mild abrasive but don't want to damage soft metal surfaces or change their dimension. The soda dissolves when washed in warm soapy water leaving no abrasive grit behind. I also took precautions to tape off oil galley holes just to be sure:

Soda blasting engine case

[irobertson]

Originally Posted by sjf911

Which main bearings are you using? I had a similar issue with Glyco replacements and finally had to go with Porsche mains sourced from the dealer.

I got the Glyco bearings from our host, for both rods and mains.

[irobertson]

Originally Posted by TT Oversteer

Soda blasting is a great way to clean cases and aluminum castings where you need a mild abrasive but don't want to damage soft metal surfaces or change their dimension. The soda dissolves when washed in warm soapy water leaving no abrasive grit behind. I also took precautions to tape off oil galley holes just to be sure:

Soda blasting engine case

I still have to clean my cam towers, and I plan on giving soda blasting a try on those.

[sjf911]

Originally Posted by irobertson

I got the Glyco bearings from our host, for both rods and mains.

Quite a few people have had issues with the Glyco bearings being out of spec. The official Porsche bearings were spot on, PP took my Glyco's back without question. The Glyco rod bearings surprisingly spec'd out fine for me.

Main Bearing Clearance

[irobertson]

Originally Posted by sjf911

Quite a few people have had issues with the Glyco bearings being out of spec. The official Porsche bearings were spot on, PP took my Glyco's back without question. The Glyco rod bearings surprisingly spec'd out fine for me.

Main Bearing Clearance

Just checked with the local Porsche dealer on a set of main bearings.
Yikes - $1100.
They sell 2 sets, 1 thru 8, or 2 thru 7.
So you can't buy #1 without having to take the #8 as well.
WTF is that? Feel like I'm buying hot dog buns?

[irobertson]

I discovered I was missing a couple of studs and the alignment pin for the #8 bearing.
I got the parts this week from Mark Motors in Ottawa, and I'm now back in the game.
Although I had previously derived the mains clearances using measurements and calculations. Today I did them with Plastigauge, which resulted in consistent clearances of 0.0025.
I wanted to do both just to be safe.
Tomorrow the plan is to seal up the case, finally.

[irobertson]

I'm wondering about installing the flywheel end crank seal.
Should I do this when mating the case halves, or wait and press it in after they are mated?

[ozracer]

Post some pics as you go along i like your attention to detail this should be a great build. Are you building to oem spec or have you planned some performance upgrades?

[efhughes3]

Originally Posted by irobertson

I'm wondering about installing the flywheel end crank seal.
Should I do this when mating the case halves, or wait and press it in after they are mated?

I waited until after the case was mated.

[irobertson]

Today I got the case halves mated.
I sealed it based on Henry Schmidt's recommended procedure.
Loctite 574 on the main bearing webs
Threebond 1104 on the case perimeter
Threebond 1211 on the #8 bearing O-Ring
Flywheel seals are dry.

I found the 1104 on the case perimeter didn't go on very thick when rolled with a foam roller, and started to dry too quickly. I ran a thin bead around and spread it with a foam brush instead. I used the same method to apply the 574 as well.
I still found the 1104 was skinning over a bit, so I went back to the first edge I did and ran over it again with some additional sealant.

Once the halves were torqued up, I had a tiny bit of squeeze out, less than I expected.
If any of you guys have done this, please have a look at the pics below and let me know your thoughts.

[irobertson]

Pic 2

[irobertson]

[irobertson]