Looking for options on 2.2S rebuild
 

Well, most of the results are in on the damage done. To date:

Two spun S (nitrited) rods, one is junk, the other is marginal. Machinist has good used replacements at $50 apiece.

One crank rod journal is toast. Options are to weld up and regrind crank, or replace with a std/std used one he has on hand at $250.

Oil pump is lunched. Spare is available for another $250, but all he has are pre-76 pumps like the one being replaced.

Aluminum gear and one of the two steel chain gears on the intermediate shaft need replacement. Another $175.

Case is currently being evaluated, but there are issues with the crank bore - bearing #7 shows abnormal wear (to the copper) in the centers. This wear pattern is also present on most of the other shells but nowhere near as bad as #7.

So -
We're nearly at a grand for replacement parts already, and still have to address all of the other consumables needed for the rebuild. If the case requires a line bore and oversized bearings, that cost could escalate quickly.

On the good side, I have practically new 2.2S pistons and cylinders, heads and other top end stuff in excellent shape, and a fully rebuilt 2.2S MFI setup with less than 5K miles on them.

Looking at Uncle Zak's recent posting for a practically new 2.7RS bottom end for $1,600 got me thinking about replacing my case and internals rather than rebuilding myself, dependant on the ability to find something like Zak's offer that would fit my 2.2S cylinders. I have seen the references to using 2.2S components with 2.4 long stroke cases, but what actually is the benefit(s) of this setup in displacement / horsepower / street performance?

If I had unlimited budget, I would really like to build one of those 2.8RSR type motors that Grady talks about, but at this point $$ take a lead role.

Sigh... maybe someday.

Thanks for your help and advice.

A few thoughts:
-If the 2.2S is for the '72T, then I am guessing originality/numbers matching is not an issue. That's good, b/c that case is probably going to measure out to be trashed. Proper repair will involve resizing the case back to standard - $1k+.
-Do not replace just one of the steel chain sprockets- replace them both. Only $35 more, and you won't risk weird wear patterns from one side to the other. Be sure to replace the cam sprockets too.
-$250 for a used oil pump is out of line. I've been picking them up for ~$75 in good used condition. This is the later 4-rib style which is good for the oil bypass mod. His other prices sound pretty good though.
-As far as using 2.2 components on a 70.4mm crank - the main benefit is simply increased compression. There is no effect on displacement. Torque, HP, and fun factor overall are increased with this mod. Due to the number of 2.4s and 2.7s produced, it is easy to find good used 70.4mm cranks. Go for it.

One more note though. you can't use your 66mm rods on a 70.4mm crank. The rods shouldn't be more than $100. If your cylinders/pistons/heads/cams are good then if you combine that with a good 70.4mm bottom end you'll end up with a pretty hot motor.. something north of 190hp and for not alot more than just replacement parts. Heck it could be less since I belive the 70.4mm crank is more plentiful than the 66mm one's.

I'd by a core 2.4T engine for less than $1000. Use that bottom end and bolt on your 2.2S top end.

Oh, that's what Tim said! In that case, I second what Tim said!