Another 3.6->3.8 Rebuild Thread...

[CBRacerX]

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.

[herman maire]

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.

[CBRacerX]

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.

[CBRacerX]

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 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.






Bolt Length



ARP 2000 Bolt Base Diameter



Bolt Small Diameter



Crank Done

[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

[CBRacerX]

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

[CBRacerX]

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

[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

[CBRacerX]

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!

[ONQRACIng]

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??

[SP2]

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!

[kirkf]

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

[CBRacerX]

Here is one nights work on the short block:



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



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



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.



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

[CBRacerX]

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.



I have had very good luck using this inexpensive ring compressor



Here they are, ready for install!!!



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

[CBRacerX]

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



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.



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

[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!

[CBRacerX]

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



OK, time for some rest!

[CBRacerX]

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.


Assemble, Assemble - Doh!


Interference




Grind Pump Case


Interference is gone...

[CBRacerX]

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




Short Block - meet white couch. Scary

[CBRacerX]

Here in no particular order are the threads where reference material was gathered from the group (thus far) for this project. These are only the threads that I initiated, but there are many that I read from other folks that were a big help, and I will try and note those later.

Rod Interference with Oil Pump
Rod Interference with Oil Pump

The Complete Engine Sealant Thread...
The Complete Engine Sealant Thread...

Sealing Case "Experiment" (so YOU don't have to!)
Sealing Case "Experiment" (so YOU don't have to!)

Reusing New Rod Bearings in Diff Rods?
Reusing New Rod Bearings in Diff Rods?

964 3.8 RSR: Small End Rod Side Clearance to Piston (how much is not enough?)
964 3.8 RSR: Small End Rod Side Clearance to Piston (how much is not enough?)

Distributing Rods and Pistons by weight
Distributing Rods and Pistons by weight

964->993 On Case Oil Filter?
964->993 On Case Oil Filter?

Used Cylinders - Scratches make them junk?
Used Cylinders - Scratches make them junk?

Removing 964 Crank Pulley...
Removing 964 Crank Pulley...

Name that stud...
Name that stud...

Using 964 RSR 3.8 Pistons and Cylinders with Stock Heads and Crank
Using 964 RSR 3.8 Pistons and Cylinders with Stock Heads and Crank

3.8 Pistons - Machine and Flip required?
3.8 Pistons - Machine and Flip required?

Detailed Pics of 3.8 RS Pistons? (For Bill...)
Detailed Pics of 3.8 RS Pistons? (For Bill...)

Wrightwood Racing or Stock Gaskets?
Wrightwood Racing or Stock Gaskets?

Best 911 Engine Rebuild Books?
Best 911 Engine Rebuild Books?

Plug Wire Ends - Special angles...
964/993 Plug Wire End Orientation...

[89turbocabmike]

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