Jeff - I called JE and they recommended NOT to excercise the rings first. Like golf it's all technique.

As far as power - I drove my car today - it's a beautiful day here - and I don't think you'll be disappointed. It's running like a scalded cat.

0-60 is in a flash. And you should be making more power than mine with a higher compression and the ITB's...

Jeff,
I did a good one a couple of weeks ago. I was working on the wiring under the hood when I bent over into the trunk I hit my head on the corner of the hood and split my head open. My girlfriend fixxed me up with some Crazy glue and a bandaid. Crazy glue is an old Sushi chef trick. Keep at it man!

Yeah, I had heard the same thing, but was told by another builder who uses JE products regularly that if done "carefully" (not to the point of actually deforming the clip) it helps slightly. And it did help slightly. The first few I got on without "exercising" (that's the word I was looking for) and it was a PITA. The others I tried the trick and it was still a PITA but just slightly less. My fingers were sore though!

Sorry to see that Jeff. I gave myself a couple scratches installing the clips but nothing that bad. Anyways I took an old flatblade screwdriver that I had an extra of and cut a notch in it large enough to grab if you will the clip. I found the while still on the bench working the clip into the side of the piston in the grooves softens them enough to make installing on the motor much easier. Also if you cut the groove tight enough you can grab onto the clip by twisting the screwdriver. Then I stuck a punch into the pin so things dont go flying, work the clip in as best you can with the notched screwdriver and then with another screwdriver, need nose or your fingers you can slide the last section inside the pin bore and then snap it home.

Hope things get easier from here on in for you. FWIW I can give you a couple tips on the jenveys when you get to that point and also some more pictures of the throttle linkage plate that I made and how I modified the bellcrank arm on the trans. Get that top end together!

Cheers, Ryder

Ryder, thanks , I will be picking your brain I am sure on the ITB's, they should be here soon.

I actually notched a screw driver........ and then it notched me. Maybe it was not too happy with me! I had put a couple of clips in last week when I was checking deck height and thought "well, that was not too bad." Not sure what went wrong this time......

Too tired I guess....

Cheers

I did the same thing - although stuck the screwdriver into the fleshy, palm - man those notched scredrivers get sharp! I bled a little on the engine - figured it was partial sacrifice to the Porsche gods...

Now when people ask me if I have blood and sweat in my car I can tell them that they have no idea...

I think we need to start a brotherhood of those of us that have given blood to build motors!! Time to get Ryder to contribute I think....... :)

Cheers

Jeff,

That sucks! I was putting mine on this last weekend and just about did the same thing. Hadn't gone very far and the fingers had had enough. I ended up making a tool to insert them. I will get a picture of it. It make the on engine insertion easy and takes a little practice on the bench but is definately safer.

Lets see some pics, Mike J made on but it only worked on his 993....

Cheers

Jeff,

I will post pictures early tomorrow night.

Mike Burns at JB Racing in Florida makes a tool too -

150 or so bucks though! I may end up having to get one. I avoiding another 6hr trip to the ER has to be worth something!! This is my first go with JE pistons, better find a good way to get these in or it will be my last go.....

Cheers

after wrestling with the ones in my car - if I go JE again - that's the route I will go. (or have someone else do it)

Jeff,

This is the tool that I made to insert the JE wrist pin clips. It works great for the pistons on the engine. On the bench you need to be careful not to push the clip past the groove. I did and had couldn't get one wrist pin all the way in. Had to take it to my engine guy to smooth out. If the wrist pin is in this won't happen. I just put the wrist pin into the piston and then push the clip in. The clip is put in at an angle with the ends sticking out. They will contact the groove and you use the plunger to push the clip on. Took just seconds to get the clips in and it would be hard for them to fly away. If the part was machined it would work even better. Any questions let me know.
http://forums.pelicanparts.com/uploa...1148008625.jpg
http://forums.pelicanparts.com/uploa...1148008667.jpg

That looks just like the one that Mike made up, that I have here. The difference is in the wall thickness, which we need to change. Thanks so much for the pics! You are the man!

Mike J, lets make a few of these.

Man, my hand hurts..... :)

Cheers

No problem but I hope you are not in a rush ; I am going down to Seattle this weekend and won't be back until Sunday night. We can fire up the lathe on Monday (if I get clearance from the spousal unit) and fabricate one up. What are your shifts like these days?

A few questions about the tool:

1 - The flattened side is to clear the skirt of the piston? It looks like its tapered?

2 - Can you post the measurements of the tool, i.e. outside and inside diameters of both pieces?

Thanks very much for the pictures, that helps quite a bit.

Jeff, I have some bronze shafts left over from the last tool I made ; can we start with the tool I made or do we have to start from scratch?

Cheers,

Mike

I think we may be able to use the one you made, but with the measurements, I can source the raw stock. I am off this weekend but have my son in tow so monday is probably out, but we can work something out next week I am sure.

thanks mike (both of you!)

I will get the measurements this weekend. It needs some tweeking but will give a base for making it. This was done with just a grinder and drill press so the measurements will only be close. I think I have a clip that I can put in it and get a picture of how it fit. The taper on it was due to everything being done by hand, grind and see if it fits:cool:

I got the measurements tonight and will get them posted tomorrow. Just got too late tonight and a few issues with the rebuild.

I found that by wrapping my thumb well with duct tape, I could get enough pressure without sever pain combines with the notched screwdriver technique to get the clips in. Took an average of 5 tries per clip, but it works.

We will see how this works.

original outside diameter 26.9mm
original inside diameter 21.75mm
Out side diameter of the plunger is 21.1
On the end where the clip goes in bored out to 22.3mm
The area that is ground away altogether is 4.6 mm up the shaft, could have been just a bit more
The outside diameter of the flat side of the tube is 24.9mm and is ground back 22.7mm There is a slight taper from the 24.9 diameter to 25.1mm at the end of the tube.

I will try to add these to the picture too.
I can also send this one to you to have one in hand to look at.

A picturehttp://forums.pelicanparts.com/uploa...1148407472.jpg

Perfect thanks, I think I should be able to make the one Mike J made work for me. You have been a big help!!

Chris, thanks for the tips, still a little weary about using the screwdriver.... stitches come out this week! :)

Cheers

Okay, so the hand is getting better and I thought maybe I should risk another trip to the hospital tonight! :) I looked at the pics that Michael had posted of the tool he made and then I modified the one Mike J had made for his 993 so it would work. Man, if you are installing JE or 993/964 clips, you need to make yourself one of these. Piece-o-cake!! (you could make one for any pin combo as well, this one would work with factory 3.2 clips too). Push the clip into the "barrel" while on the bench, then tap it in to the piston. Painless, fast and easy. First try each time. The "mikes" should start making these for sale!!

The only downer is that the clip I was trying to put in when I was wounded must have taken a "flyer" across the shop and is no where to be found! Crap, gotta get another one. I guess in my panic to figure out what to do with my sleeping 3.5 year old and trying to decide if I needed to go to the hospital, the hunt for it never occured and now I can not find it. Oh well.

I got half of the Psitons and Cylinders on tonight, overall, a good night.

Here is a pic of what I got done and a pic of the tool as well!!

http://forums.pelicanparts.com/uploa...1148448376.jpg

http://forums.pelicanparts.com/uploa...1148448433.jpg



Mike, if you want to hack around on the lathe some night and drink beer (I will bring it) I have some ideas to make this tool even better. We could knock of a few at once and help all the poor folks who buy JE's or rebuild 3.6's!!!

Cheers

You are on...but we would definitely be "hacking". I am glad the tool is working for you. My car will be ready in a few weeks (paint is done, I will be mounting the new Targa top next week) so I can show off the car as well. Now that you have the tool working I guess you can wait that long?

Any how is your palm healing?

Cheers,

Mike

Sounds good!! I will source some raw stock in the next couple of weeks and some beer too!!

Looking forward to seeing the car when it is done, bet you can't wait!

Palm is getting there, stitches out later this week so all is well.

Thanks again for the use of the tool, it may have saved my life at the rate I was going :)

Cheers

Heads and tin on one side! Aren't those Ti retainers purdy? :)
http://forums.pelicanparts.com/uploa...1148507311.jpg


And a shot of the the twin plugged head!

http://forums.pelicanparts.com/uploa...1148507263.jpg

Cheers

Hey Jeff playing a little catch up are we? Great to see some progress again. Where did you get your Ti retainers from? Im just finishing nit picky stuff and hopefully put it in this weekend.

Have you gotten your ecu yet and seen the wiring harness?
p.s. I dont bleed on my motors, sweat, cuss, yell and smile but havent bled on one yet. I bled on the suspension and interior though

Springs and retainers are from John (camgrinder) I went with the race springs.

ECU and harness is still in transit. I have a wiring diagram and it doesn't seem to bad........ time will tell!

Cheers

I got my cams, race springs and retainers from John as well. Awesome guy to deal with.

Right now my harness is on the floor in my bedroom laid out with almost everything labeled. There is a lot of things I wont be using so I dont know if I will eliminate them from the harness completely or keep them around. Mine came with most things zip tied together to make going through it much easier. I have all my ignition bundled together, then injectors, sensors, power, ground, sensor ground. Just a matter of getting it in the car to cut things to length. If you dont have a multimeter get one, I found some of the wires in the harness to be a different color than what was stated on the diagram. Plus it makes double and triple checking much easier than following wires all over the place.

Also, even though I didnt do it I think I will in the near future. Instead of adapting the existing throttle system to work with the Jenvey's I want to run a cable from the pedal all the way back to the engine bay and the crossbar linkage.

Cheers.

John does all my cams and rockers, always been happy with his products.

Interesting idea on the throttle......

I have 3 multi meters, so I should be okay! :)

I will still need to make up fuel lines, ignition cables and all that sort of stuff too.

Now I am thinking my Fan and Housing are a little pitted so they may need to be replaced...........

Cheers

Still making progress! Thanks to Troy and Guy at EBS (who help me out alot) I got the missing clip overnited to me!! Thanks guys. So I put the remaining Pistons and cylinders on and the heads. Powder coated cooling tin in place on both sides as well.

Here is how she sits now!

http://forums.pelicanparts.com/uploa...1148623458.jpg

http://forums.pelicanparts.com/uploa...1148623472.jpg


Cheers

Got a little more done this morning. Installed cam towers and torqued down the heads. Cams spin freely in the towers. Hope to get the shafts, seals and rockers in tonight and tomorrow night along with ramps, chain boxes and sprockets.

http://forums.pelicanparts.com/uploa...1148756254.jpg

http://forums.pelicanparts.com/uploa...1148756274.jpg

Cheers

Wow - Look great! and clean!

Thanks Jeremy!

Here is the rockers ready to go in tomorrow night. Too tired now, and we all know what happens when I work on things when I am tired..:rolleyes: (these were rebushed and ground by camgrinder)

http://forums.pelicanparts.com/uploa...1148875723.jpg

Cheers

Great pics and info! Keep it coming!

Got the rockers and shafts in tonight with the RSR seals. Pulling the old RSR seals out of the shafts really sucks!!! Digging them out of the grooves is a royal PITA!!. There is also clearly more than one mfg of the seals as this set (from EBS) seemed to be of a higher quality. They seemed to be much more uniform and consistent in shape etc.

I will post pics tomorrow showing the install and also the setting of the sprocket parallelism. I think it may need some adjustment as I am using new cams, thrust plates and sprockets.

Cheers

Hey Jeff looks good I am only slightly ahead of where your at on the rebuild. Should be firing it up tomorrow. I am going to post the rebuild in the next few days. Sneak peek.
http://forums.pelicanparts.com/uploa...1148971856.jpg

Looks really nice! Keep us posted after the start up!

Cheers

Cams are in and timed now and the the long block is basically buttoned up. Just waiting for a few more things at the powdercoater and the expensive stuff to show up!! :)

http://forums.pelicanparts.com/uploa...1149658931.jpg

http://forums.pelicanparts.com/uploa...1149658943.jpg

Cheers