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