After a long time, it has begun! rebuild yay
 

Ok so after years of farting around with ideas to rebuild the motor and do this and that and crazy stuff, then stupid stuff then normal stuff I finally got my money man (dad) set on a motor. It's his car for now but we will be doing some family car swapping and buying and selling soon, ergo it will become mine.

Anyways we are starting off with a 1978 3.0l cis motor which after teardown I found to be pretty much stock. We added msd and it came with SSi's. The plan is as follows from the bottom on up:

ARP rod bolts
Stock rods
100mm JE pistons with 10.5:1 CR
100mm LN Engineering nickies cylinders
ARP headstuds
Racing type chains (from EBS)
DR camshafts, modS on 108 lobe centers
Port matched and flowed twin plugged heads, stock valve sizes
DR camshafts racing type valvesprings with Ti retainers, what a deal
Solid tensioners
993 heat exchangers modded to work with the older heads
48mm Jenvey taper ITB's
Fiberglass shroud
Powdercoated engine tin
Crankfired ignition, still kinda up in the air on which system

All the proper machine work will be done to the case, heads, crank, rods and rotating assemblies by a nice guy running a machine shop in Costa Mesa.

Some parts will be powdercoated and some wont. The oil pump is still to be decided, I might have a clean 930 pump available or shell out for something else like a gt3r, who knows. After reading some recent posts about the Tec3R I am a bit reluctant to go that route, I have talked with Souk at Motomotions about his system and its in discussion here at home. All the little bits and pieces we arent using will be sold here on the board.
Fun little short stroke 3.3, cant wait to get the parts back and start building it. I have some pics from the teardown and I will be posting those along with during and after photos. So what does everyone think?

If we went with a 3.6 it would end up costing about the same and this route the whole engine is fresh and done the way I want it to be done. Plus the 3.6 is becoming rather common ergo its a little boring. Dunno, it never really came across as a very attractive option.

Ok so yesterday went and picked up a set of 993 heat exchangers and the FG fan shroud from Pete at Rennspd. Great guy and great coincidence he had the exhaust that I wanted. he has a pretty slick little car he is building up right now, wont let the cat out of the bag thats for him to do.

Anyways, parts are gone to the platers and powdercoaters, then back home to wait for the cylinders from LN (through EBS) and then to the machine shop.

Picked out the throttle bodies but still being a little weenie on the EFI system, I head this I hear that, I have to make up my mind soon though. All the parts being powdercoated are being blasted and then coated with clear for a factory kinda look with exception of the fan and the valve covers, that was on dad's insistence. Pics as soon as I get parts back.

If anyone is actually looking at this..........

Been lazy with the camera I know, sorry, there will be a big update this weekend.

Update: got my first shipment from EBS, arp headstuds, rod bolts, full gasket kit, racing timing chains, engine sheet metal hardware, case hardware, oil sump plate cover, RSR style rocker arm shaft seals (little shipping hiccup but no biggie) and some stickers.

Next shipment holds, hopefully, some JE 100mm pistons in 10.5:1cr setup, solid chain tensioners, the LN nickies will show up when they show up.

Also have the oil lines, and some other odds and ends on hand.

The case is being powdercoated after some walnut shell media blasting prior to heading off to the machine shop.

I have pretty much finalized the EFI setup and cant wait for that stuff to show up. I am stoked to get moving on this project. Also in store is a late style 915, all aluminum with the 8.31:1 R&P ratio fully rebuilt from PowerhausII.
Wevo engine mounts, solid tranny mounts, SRP oil breather catch tank, some mil spec quick disconnects for the wiring, new fuel pump, new fuel lines (braided most likely earls) and other little things.

I have been using my car to mockup my shifter linkage and am pretty close to having it dialed in. I am taking over this car once dad gets his GT3 so mine is up for sale (rolling 1972 911t). All the suspension mods will then go into the 74, coilovers, monoballs, rollbar/cage. Whatever, I know you guys wants some pics and you will have em, just bear with.

Cheers, Ryder

pictures
 

Took the studs out of the cam towers this evening, cleaned up a little and playing the waiting game on parts. Should have parts back from the powdercoaters this week. Also getting my cams and raving springs with Ti retainers. Getting another package from EBS with my rocker arm shaft seals, solid tensioners and oil sump plate. The JE's and LN's still dont have an ETA. Ordering my Jenvey's and EFI setup this week and hopefully that will be here by the time the cylinders show up and can go to the machine shop with them. Otherwise not really a lot going on.

Took a look at some of the main bearings and that check out, the auxiliary shaft bearings on the other hand or not in good shape. The aux. shaft itself has some reasons for concern. One of the timing chain gears shows considerable wear and the main gear itself has some metal taken out of it, I am guessing this is from the timing chain rubbing on it and attribute this to the fact that the chain tensioners could be compressed by hand and the safety collars were pushed all the way to the top of the tensioner shaft. So here are some pics of the goodies I have gotten so far and what I have taken apart.

Ryder

http://forums.pelicanparts.com/uploa...1141022728.jpg http://forums.pelicanparts.com/uploa...1141022765.jpg http://forums.pelicanparts.com/uploa...1141022790.jpg http://forums.pelicanparts.com/uploa...1141022814.jpg http://forums.pelicanparts.com/uploa...1141022845.jpg http://forums.pelicanparts.com/uploa...1141022889.jpg http://forums.pelicanparts.com/uploa...1141022915.jpg http://forums.pelicanparts.com/uploa...1141022939.jpg http://forums.pelicanparts.com/uploa...1141022998.jpg

pictures
 

best craftsman tool
http://forums.pelicanparts.com/uploa...1141023107.jpg

motor stuff
993 heat exchangers
http://forums.pelicanparts.com/uploa...1141023137.jpg

http://forums.pelicanparts.com/uploa...1141023174.jpg

http://forums.pelicanparts.com/uploa...1141023271.jpg

http://forums.pelicanparts.com/uploa...1141023314.jpg

and lastly my work bench

http://forums.pelicanparts.com/uploa...1141023346.jpg

if you cant tell my dad really likes porsche posters, the whole garage is covered with them. have a nice sunday evening fellas.

looks good. i cant wait to see it!

Looking good! What EFI did you go with? Inquiring minds want to know!!! :)

Cheers

On the EFI front Mike and I from motomotions have been having near daily email convo's. I started leaning one way and so did he without really knowing what the other was thinking. I am dead set on going with the Autronic SM4 at this point. I plan on using the Bosch injectors and hopefully Bosch coilpacks as well. The Autronic is said to be designed with a bias towards Bosch parts. Also it will support a Motec or other aftermarket dash system that datalogs no problem. more later

Could you PM me the details on it? I am interested as well. I have a couple of "joint projects" with Mike and Souk right now! Does it use the Bosch VR6 coil packs?

Cheers

Sounds like a fun motor. I will be interested to see how your EFI project continues.

btw, who did your shroud?

Is this for a track car only? I don't see how you would ever get it past the smog police here in California?
steve

The car is a 1974 model, no smog needed thank goodness. The fan shroud is from Pete at Rennspd.com really cool guy.

So the basis of the motor is a 78 3.o but the car is a 74. What most of us would give to have a smog excempt car. Sounds like it is going to be very fast. Any guess on dyno numbers
Steve

ive got a 1972 911t roller you could build into a fun smog exempt hot rod!

i hate this waiting for packages and I just want to get cracking at putting this thing together. Took care of the tranny situation, super late style 915 bog, totally rebuilt from Powerhaus II, classy operation

Any progress lately?

Well, my case, crank, rods, rod bolts, headstuds, pistons, cylinders, heads, cam towers, oil pump, intermediate shaft, fan, fan housing, flywheel, exhaust, valvesprings, ti retainers and piston rings are all at the machinists as of this past saturday. Still waiting on my jenvey's to show up and the electronics which should be soon. Tranny will be showing up soon as well I suspect.

In the meantime I am taking care of the oil breather tank, making a new engine wiring harness, cleaning up the existing wiring, rebuilding my axles and drilling the inner mount flanges for a different trans.

Also need to get my fuel accumulator and fuel filters mounted, put in the new fuel pump with new wiring, get the new starter ready, throw on the heat shield, polish the new M&K muffler when it gets here, uh put the final touches on the little throttle linkage, throw on the rear monoballs, got all the new shifter bushings and stomski shift link piece in.

Need to figure out where I want to mount my coilpacks and ecu and get those pieces made and ready for install. I am just putting together all the little touches while the motor is off at the machine shop so when it gets back I just need to assemble it, put it in the car and figure out how to use efi lol.

I didnt want to take anymore pictures until I got parts back from the machinist plus the other goodies arent even here! As soon as the new parts show up and the bits come back from John there will be plenty of big progress. Now its just those little things that make it your own ya know.

cheers

a little update.....
 

been cleaning, starting to run wiring, waiting on parts to come back from the machine shop, the jenveys are scheduled to arrive today, little things here and there. Thought I would show a little engine bay bling even without a motor in it...

http://forums.pelicanparts.com/uploa...1145644085.jpg

with coils and ignitors...
http://forums.pelicanparts.com/uploa...1145644120.jpg

the brains behind all this...the plate the sm4 and expander are mounted to bolt down onto 4 rubber isolator mounts, in the pic it almost looks flush with the carpet.
http://forums.pelicanparts.com/uploa...1145644152.jpg

got bored, made a little decklid prop out of some alu tube notched at each end...
http://forums.pelicanparts.com/uploa...1145644194.jpg

wires starting to make their way out...
http://forums.pelicanparts.com/uploa...1145644219.jpg

if i get to pickup my motor parts tomorrow there will be more pics, if not then maybe some shots of the jenveys lol

have a great weekend all, cheers

BEAUTIFUL engine bay! What's that gold stuff you used???

I LOVE that engine bay. I may have to do the same thing in my VW

Its gold heat reflective foil. I got it from hrp on the web. Awesome stuff but a pain to get on right.

more stuffs...
 

the induction

http://forums.pelicanparts.com/uploa...1145850866.jpg

http://forums.pelicanparts.com/uploa...1145850898.jpg

crazy powdercpoated color...
http://forums.pelicanparts.com/uploa...1145850938.jpg

muffler from ben, pre finishing and without tips welded on, for 993 heat exchangers.
http://forums.pelicanparts.com/uploa...1145850991.jpg

and my artsy desktop pic
http://forums.pelicanparts.com/uploa...1145851098.jpg

fitted fuel filter and accumulator, cut braided hose to length, mounted new pump, ripped out more wiring, clutch cable, speedo cable, ran some power lines and wiring. should have parts back this week and start putting an engine together.

Comming right along! looks good!

Cheers

Ok so on friday headed down to the machine shop. Cleaned out all oil galleys in the case, washed it about 5 times. Chased head stud threads. Chased the threads for the cam tower cover studs as well, talked shop, checked out a 935 throttle body that was hanging around and did some more cleaning. John balanced the rods and we did some other clean up and little tricks here and there. Still waiting for the new valves to show up and thats it. So sunday will be spent finishing the wiring for the ecu and engine harness, possibly pick up the engine parts but most likely that will be monday. Maybe get the trans installed. Thats really it for now, nothing too exciting I know. Did get a chance to look at some internals on some awesome factory race motors though, pretty neat stuff.

Great looking set of parts and engine bay. You are doing a super job! http://pickettweb.com/icon/burnout.gif

Dear Santa, I've been pretty good all year--well maybe a couple of slips here and there but, if you could just slip one of those cool Jenvey induction units under the tree. I promise.........

picked up the parts from machine shop...
 

Well tried to get the bottom end together this weekend but federal mogul decided to put the wrong bearings in the right box so I couldnt put the rods on the crank. Started putting the clips into the JE pistons and what a bear that can be. There must be a better way! Got most of them on but I need to order some more because one went flying around the garage, got the rings on the rest. Popped the oil pump and intermediate shaft into the case with the main bearings, cleaned up the distributor hole for the plug. Thats really it just waiting for new rod bearings to show up.

http://forums.pelicanparts.com/uploa...1147066502.jpg

http://forums.pelicanparts.com/uploa...1147066538.jpg

[img]http://forums.pelicanparts.com/uploads7/IMG_00131147066570.jpg[/
img] http://forums.pelicanparts.com/uploa...1147066645.jpg

http://forums.pelicanparts.com/uploa...1147066696.jpg http://forums.pelicanparts.com/uploa...1147066722.jpg

http://forums.pelicanparts.com/uploa...1147066751.jpg
and the neat little heater adapter pieces.

more to come as things move along. cheers!

more...
 

http://forums.pelicanparts.com/uploa...1147066983.jpg

http://forums.pelicanparts.com/uploa...1147067005.jpg

LN stuff is great!
http://forums.pelicanparts.com/uploa...1147067036.jpg

notched the screwdriver to aid in getting the pin clips in a bit easier, doesnt work all that great, did 4 without problem but the last 2 are kicking my ass.
http://forums.pelicanparts.com/uploa...1147067103.jpg

well hopefully things go quickly this week. i want to have the bottom end together asap, then p&c's, top end and timing. engine tin with the cutouts for lower plug wires, fit the fiberglass shroud, final fit for the engine wire harness, stick the trans in the car, hookup some more wiring, more wiring, a little plumbing and other odds and ends.

It's always nice to see progress, isn't it?

Things are looking good.

Those clips are a real pain. I made a simple tool that made it much easier. Take a look at this thread.

http://forums.pelicanparts.com/911-engine-rebuilding-forum/258950-je-piston-pin-cilps.html?highlight=clips

Good Luck!

Thanks a ton for that link, I remembered there was something somewhere about this. I was wondering if it really was possible to install the pistons to the cylinders and then connect to rod to the piston and now I see it can be done! I hope my rod bearings showed up today hopefully some progress can go on. I did have some time to swing by my old shop and fab up a bracket to mount on the trans and take a cable pull from the bellcrank to actuate the crossbar linkage on the Jenvey's.

No problem - good luck with the rest of the build. Sounds like a great engine.

How about a pic or two of the bracket for the throttle?

Looks good by the way!

pics of progress
 

jeff i knew youd want that sooner or later. here goes and a little progress.....

http://forums.pelicanparts.com/uploa...1147155005.jpg

http://forums.pelicanparts.com/uploa...1147155046.jpg

http://forums.pelicanparts.com/uploa...1147155164.jpg

The only other thing I am going to do is shorten the bellcrank arm and move the outer lever inboard just next to the inner arm. Then its drill a hole in the upper plate, route the cable and call it a day.

Now motor pics, got the bottom end together tonight, tried installing one of the JE's into the LN cylinder and its a bit tricky because the base of the LN has a chamfer towards the inside of the cylinder. I think I will just tack weld a small bit of metal to the piston ring compressor band to keep it from sliding in with the piston.

http://forums.pelicanparts.com/uploa...1147155412.jpg

I was really happy with the way the plated pieces turned out. Really happy we did it especially the through bolts.

http://forums.pelicanparts.com/uploa...1147155458.jpg

http://forums.pelicanparts.com/uploa...1147155531.jpg

this was my first time using 1104, yamabond I hear its the same, sealant. I really like the stuff, it went on easily and just a tiny bit squeezed out all around the case. I was very happy with how uniform and minimal it was. Hopefully it will always look this clean on the bottom.

http://forums.pelicanparts.com/uploa...1147155570.jpg

http://forums.pelicanparts.com/uploa...1147155639.jpg

wow

no need to say more.

Looks good, thanks. I will be interested in watching your progress, you are a little ahead of me! Got the fuel lines all figured out yet? Are you using a regulator?

Cheers

a wee bit o progress
 

Fuel lines are pretty much figured out. I just need to have the regulator show up so I can plumb it in thats all, oh and replace the pump and other little things. I got the whole left side on the engine tonight, all the cylinders are on on the right, just put on some heads and cam towers over there tomorrow and start timing.

Deck height checked out to be withing what I like, what my machinist likes, what some friends like that build these motors as a means of making a living, what I have heard from others that are reputable so some might think its a smidge low but I checked everything. Deck height checked on 4 cylinders, piston to valve clearance checks out as well, piston dome to head surface checks out too.

So things are picking up steam still going slower than I would like. Hopefully this weekend I can have it buttoned up and start fitting the shroud, get the intakes and exhaust on, get it in the car along with trans to finish wiring.

Oh and modded the oil breather plate and mounted the oil temp sensor there. Looks like it belongs.
Cheers all, some pics, fun and some goofey.

http://forums.pelicanparts.com/uploa...1147328275.jpg http://forums.pelicanparts.com/uploa...1147328287.jpg

http://forums.pelicanparts.com/uploa...1147328317.jpg

http://forums.pelicanparts.com/uploa...1147328344.jpg
couldnt resist seeing how it will look.
http://forums.pelicanparts.com/uploa...1147328369.jpg

new valves, seats, bases, springs, retainers, seals and guides. valves and guides are from SI which make some awesome stuff like the finned 935 style valve guides that I got and those valves that happen to be awesomely priced with tons of cool features lol
http://forums.pelicanparts.com/uploa...1147328408.jpg

so need to figure out some wiring and get back to it.

Porschekid,

Looking good so far. Most impressive.

Just an FYI: Don't think the oil temp sensor will work in that location. I believe that the sensor needs to be submerged, or at least in the path of the oil. In the breather loaction, at best, it'll receive some oil splatter, but mostly warm air giving innacurate indication of true oil temp........don't know if you are planning on using its input for EFI, or just for the dash gage.

Good luck with the rest of the build. Looking forward to updates.

Would it be better placed in the chain box cover?? Any other ideas about where to install it?

Thanks

You can get creative, i guess, but I'd say just keep it in the original location, in the path of the oil to the tensioners/cam towers. Whatever you do, just make sure its either in the oil path, or submerged.