IT'S ALIVE.... 15 months later!!!!!!!!

Groovy911SC · 01-17-2005, 01:02 PM

Well, I started my 1980 911SC 3.0 stock rebuild for the first time!!!! It did take over 15 months to complete! ( I did also rebuild the brake system, rebuilt the entire front and rear suspension, added "through the body" front sway bars... new rear sway bars). I will not will any points for speed here but so far, all I have encountered was a small oil leak in the forward left side of the engine. Looks like a loose oil ling plug or the top valve cover was not tight.

Anyway, I'd really like to thank everyone who has helped me out during this project. I asked many silly questions and everytime some responded with a patient response that helped guide me through this rebuild.

I am so pumped that the engine started on the second crank (after properly priming the oiling system). Wayne's book really gave me the confidence to take on such a project. I mean, up until this project, I've never seen the inside of even a Briggs & Stratton lawn mower engine before let alone a Porsche engine!!!!!

Again, thanks to everyone for contributing to this forum and to our host Pelican Parts and all who work there!!!

I'm off to change the oil and find that !@$@%$% leak...

Walko · Walko's Garage

PICTURES OF THE REBUIlD

Michael

asphaltgambler · 01-17-2005, 01:05 PM

That's great!! Do you have pics to post of the project from beginning to end? I'm sure everyone here would love to see them and read about any mistakes or interesting stuff that happened along the way.

jpnovak · 01-17-2005, 02:27 PM

That's the type of story we like to hear. REbuild your 911 motor. no experience necessary.

Groovy911SC · 01-17-2005, 02:59 PM

Here are a few pictures of "early on" in the project...

Look at the crank shaft below... beautiful right?? Wrong... the local machine shop ground the crank for me at .25mm. When I sent the unit out to EBS Racing for re hardening and polishing it seems that the grind was so bad it could not be polished back to spec!!! Lesson learned... if they haven't done the work before, don't be the the guinea pig!!! Experience is worth every penny. Now, what to do with the ruined crank... door stop? I had to source a standard/standard crank, Not a cheap proposition!

Look at that Kick Azzzzz oil pump!!! Came out of a 14000 mile 993! Bench tested at EBS

Intermediate shaft re-conditioned, all new gears, new nose bearings and seals, new timing chains. I do however feel like I made a mistake in purchasing the chain and rod holders. They were very expensive. I could have made them easy enough. Oh well, more lessons learned.

Notice the new steel cylinder studs. They ROCK!!! However, the old ones were a pain to remove. I'll eat some poison before I do that again!!!

Notice the pertty orange line!

The engine was fitted out with JE Pistons from Pelican (circlips sucked), 9.5-1 comp, re-plated Mahle cylinders (EBS Racing), Cylinder heads have new springs, new intake and exhaust valves reground to stock by Memphis Motor Werks. The connecting rods used stock bolts etc and were re conditioned by EBS Racing. Cam shafts were brought back to stock by Elgin cams. Rockers were reconditioned by Competition Engineering - very nice guy! All hardware and other new parts from Pelican ( I spent a butt load with Pelican, worth every penny). I changed the rubber gaskets on the intake manifolds and a gasket on the air intake unit?? I did not do too much on CIS, which may be a mistake later on. New Vacume hoses everywhere I could. I had the front mounted and engine mounted oil coolers ultrasonicly cleaned and replated at Pacific Oil Cooler. Engine tins bead blasted and repainted. That is it for now. I'll try to located more pics.

magic930 · 01-17-2005, 04:10 PM

Congratulations on the rebuild. Hope your leak is not serious, keep us posted.

Crowbob · 01-20-2005, 10:47 AM

Congratulations! Good luck on the leak. Thanks for the tip about the rod and chain holders. Help me prevent the same mistake by borrowing yours!

Groovy911SC · 01-20-2005, 11:08 AM

Jim just email me and I will send them on.

Update on the leak. It seems oil leaks when the engine is running from the back of the cam tower housing. Precisely from the plug where the original plug was removed to clean the internal hard oil line in the cam housing that lubes the rockers.
Now would that make you mad? I took my cam towers to a machine shop to be disassembled and cleaned. I bought NEW plugs so the machinist would not have to make new ones. I called the guy and he seems to remember one of them not fitting very well. Holy crap! Could I have picked a worse machine shop (again)?
My first instinct is to JB Weld the area after cleaning it very well. It only leaks when the engine is running. It does not leak very much. Just enough to drop oil on the heat exchangers and smoke slightly during the burn in peroid (20 mins at 2000 RPM).
Opinions?

Crowbob · 01-20-2005, 11:26 AM

I'll email shortly. And thank you. Did the shop put RTV on the plugs prior to pressing them in? I think I heard people do that for insurance against what just happened to you.

adomakin · adomakin's Garage

congrats on the rebuild! you could try the jb, its not going to hurt-just got to make sure the area is super clean for good adhesion

Andy