Pelican Parts Forums - Another 3.6->3.8 Rebuild Thread...

Pelican Parts Forums (http://forums.pelicanparts.com/)

- 911 Engine Rebuilding Forum (http://forums.pelicanparts.com/911-engine-rebuilding-forum/)

- - Another 3.6->3.8 Rebuild Thread... (http://forums.pelicanparts.com/911-engine-rebuilding-forum/267356-another-3-6-3-8-rebuild-thread.html)

LN engineering has them, and I am happy with the quality and weight. And Charles has been a very helpful person with my project so far.

Chris,
How's the rebuild coming along?

Did you end up buying all that 3.8RSR stuff on ebay you posted a while back?

I was following auction just for fun just to see how much the stuff would sell for then they all ended early.

The RSR ebay stuff was not me. I would have liked to get the pistons as spares - but someone apparently bought everything before the auction ended. I am now waiting for my R&R Rods from LN Engineering. Once I have those in house, I will deck height all the cylinders and decide if I need to make other changes.

My R&R rods from LN Engineering arrived on Friday and I got some time to put them on the crank today. First I had to take the recently assembled bottom end apart (ugghh), since I could not get my rod bolt stretch guauge on the bolts otherwise. So I will be cleaning that up and doing the case assembly again :mad: I will start a separate thread on what I found taking a freshly sealed case apart without running it - some sealant issues are interesting!

The rods are nice, but the weights are not as close as the factory rods (will post weights later). I got them installed on the crankshaft without incident.

http://forums.pelicanparts.com/uploa...1157328770.jpg

http://forums.pelicanparts.com/uploa...1157328792.jpg

Bolt Length

http://forums.pelicanparts.com/uploa...1157328812.jpg

ARP 2000 Bolt Base Diameter

http://forums.pelicanparts.com/uploa...1157328836.jpg

Bolt Small Diameter

http://forums.pelicanparts.com/uploa...1157328863.jpg

Crank Done

http://forums.pelicanparts.com/uploa...1157328888.jpg

Hey Chris,
Excuse me if this a "well duh!" comment, but is up with the measuring of the rod bolt length with the calipers instead of something more accurate?
I keep a record of unstretched rod bolt lengths in case I reuse the rod bolts later.
-Chris

Quote:

Originally posted by ChrisBennet
Hey Chris,
Excuse me if this a "well duh!" comment, but is up with the measuring of the rod bolt length with the calipers instead of something more accurate?
I keep a record of unstretched rod bolt lengths in case I reuse the rod bolts later.
-Chris

I did the record of the unstretched lengths using this caliper, since it was fast and repeatable. I used a micrometer on the previous pass that was a bit tedious and didn't get me much more precision.

FWIW, the bolt lengths only varied by about .002-.003 mm

Some more progress

OK, got to spend some time while the wife was on a biz trip getting the case back together (again!), used the warm family room for this... I then took half a day on Sunday (and a late night) getting things further along. I now have almost a long block, still need the cam boxes, rockers and the like installed. But finally more progress! Pics will follow to make post complete :)

http://forums.pelicanparts.com/uploa...1163457166.jpg

Chris,
I am in SE PA, and I envy you!! If I brought my 3.7 build into my family room, I would be living in the race trailer!!
Andrew

Quote:

Originally posted by ONQRACIng
Chris,
I am in SE PA, and I envy you!! If I brought my 3.7 build into my family room, I would be living in the race trailer!!
Andrew

It was all gone when she came back from the trip - shhhh!

Actually, it was still set up, and my wife helped me do the case seal. But then she banged her shin in the vincinity - and it was back to the garage for the whole setup, quick!

My crew Cheif (wife) also gets her hands dirty on the rebuilds, but I have been told that I am only allowed to bring the slicks in fron the cold. I was going to try and convert the walkin closet into an engine/gearbox room, but the smell might give it away, unless I use the sock odor to mask it.. Hmmm... An idea??

What a fantastic thread! I am doing a resealing of my SC engine, with no rebuild and it is so depressing seeing how dirty my engine looks compared to yours! :)

I dream of doing a complete rebuild like you one day with all clean and machined parts. Just fantastic! :):)

Seeing the pics of your engine hanging over your hardwood floor made me laugh. I would get killed for that in a hurry!

I've got about 700km on my motor since I finished the rebuild, but I am taking a bit of a break from porsche work. I have a leak at one of the oil lines by the thermostat, and I am too lazy to fix it right now. (That and it keeps snowing here which saps my energy.)

Kirk

Required Imagery

Here is one nights work on the short block:

http://forums.pelicanparts.com/uploa...1163552440.jpg

Mahle RSR Rings - if you look very closely they say Goetze on them...

http://forums.pelicanparts.com/uploa...1163552528.jpg

Factory 964 Wrist Pin Circlips. These did NOT fit the RSR piston, the wire was very slightly too large.

http://forums.pelicanparts.com/uploa...1163552599.jpg

The circlips provided did not fit either, the end with the locking tab stuck out too far when in the locking groove. Sigh. So I had to modify each one with a dremel cutoff wheel.

http://forums.pelicanparts.com/uploa...1163552697.jpg

Here is the RSR lightweight piston and ring set ready for assembly

Images Continued

http://forums.pelicanparts.com/uploa...1163552796.jpg

After checking the ring gaps, installed rings on piston by hand, did not use a spreader tool. I installed the circlip in the right side of each piston.

http://forums.pelicanparts.com/uploa...1163552851.jpg

I have had very good luck using this inexpensive ring compressor

http://forums.pelicanparts.com/uploa...1163552900.jpg

Here they are, ready for install!!!

http://forums.pelicanparts.com/uploa...1163552941.jpg

And here is 1-3 bank, with heads matched...

http://forums.pelicanparts.com/uploa...1163553316.jpg

The fun really begins - getting those blasted pins installed. Note the anti-contamination wrap (oxford cloth shirt)

http://forums.pelicanparts.com/uploa...1163553425.jpg

Whew! One bank down. I used Curil K-2 on the base of the cylinders instead of a sealing ring, case was machined for larger 102mm jugs.

http://forums.pelicanparts.com/uploa...1163553455.jpg

Got the anti-knock bridge installed loosely. But I did not remember to put the lower air deflectors on...

http://forums.pelicanparts.com/uploa...1163553619.jpg [img]

Fortunately, I had removed the deflector mount studs for case machining, so I was able to slip them in after the heads were on. Ready for cam towers!

End of the night

http://forums.pelicanparts.com/uploa...1163555101.jpg

Heads and Cam towers on and torqued. Note the baby monitor, I am also watching the 2 year old :D

http://forums.pelicanparts.com/uploa...1163555123.jpg

OK, time for some rest!

Here is the sequence used to fit the R&R Rods into the case. I assembled the crankshaft, then installed the oil pump and intermediate shaft, etc in the case. Installed the crank, assumbled the case and installed pistons and cylinders on 2,3, 5,6 and checked for interference. There was some interferance with the oil pump. Since the rods had been balanced already, I chose to clearance the pump. Carrillo rods are the same shape, and they require either grinding the rods or clearancing the pump 0.5mm. Once I finally decided to do it, the clearance was easy to get, and I got a look at a disassembled pump to be sure I was not removing material in a thin area.

http://forums.pelicanparts.com/uploa...1163569555.jpg
Assemble, Assemble - Doh!

http://forums.pelicanparts.com/uploa...1163569579.jpg
Interference

http://forums.pelicanparts.com/uploa...1163569651.jpg
http://forums.pelicanparts.com/uploa...1163569736.jpg
http://forums.pelicanparts.com/uploa...1163569760.jpg
Grind Pump Case :eek:

http://forums.pelicanparts.com/uploa...1163569625.jpg
Interference is gone...

Prequel Part Deux

Here the case is assembled (again!) with sealant and torqued up. Wife was a big help on this part!

http://forums.pelicanparts.com/uploa...1163569909.jpg

http://forums.pelicanparts.com/uploa...1163569932.jpg
Short Block - meet white couch. Scary :)

Misc Thread Consolidation

Nice thread compilation Chris, thanks. I'll be embarking on my rebuild shortly. Can't wait to see how your 3.8 performs:)