Help Needed - 3.2SS Rebuild
 

I've begun my first Porsche rebuild on a '79 3.0SC with 85k. My plan was to do a top-end rebuild installing 98mm Mahle P&C with DC20 cams.

The engine drop went very well and so did the tear down until... I found one broken dilivar. :mad:

I removed the non-broken dilivars on the 1-3 bank by pre-heating the case with a heat gun for 30 minutes, 60 seconds of propane on the spigot and the snap-on collet stud remover - all of that went very well.

The broken stud is another issue, it protrudes about 3/16" of an inch above the cylinder mating surface or about 5/8" from the case itself (sorry no pics, I'm on the road right now). I did a search and tried the Sears broken bolt remover - I was really hoping that would work but it didn't - I impacted it on and impacted it off but it just stripped the tool - it sure shined up the dilivar though.

I think my next plan is to try vice grips. I was hoping I wouldn't have to resort to that because I'll have to remove the case through-bolts to get a turning action on the bolt.

The questions are:

- If I remove the case-through bolts will I need to split the case?

- I've seen some 'experts' on this forum recommend large vice grips. Can someone post a picture of a vice-grip (or a link) that they recommend? There are all sorts of vice-grips out there but I imagine it needs to be large and of a certain type.

I purchased a small oxy-acetyline kit to go along with the vice grip attempt. Any tips on using it?

And finally, if this fails can a regular machine shop remove the stud or should I only go to a p-car specialist? I'm thinking if it goes to a shop then I'll have to split the case and do a bottom end rebuild because I won't trust that dirt and/or debree has gotten into it.

Advice is very welcome. Thanks,

-Rob

Geez; sounds like time to take the case in for some EDM work.

If you're already there, I think I'd split the case and have EDM done. Overall, a few hundred more dollars, but you pay for a LOT of peace of mind...and you save the headache of ******* with broken off head studs :mad:

Overall, it's not a big deal...hang in there

I've read about EDM in Waynes book. Is there anyone providing that service on the east coast?

Any vice grip suggestions???

I'd go to home depot and find the biggest vice grip with a small stout body and flat teeth

Something like this
http://www.toolmonthclub.com/store/i...isegrip150.jpg

stay away from the long jaw, needle nose type, they tend to twist.

Then I would go and get a MAPP cartridge torch and give it one more go. Heat around the base of the stud - the trick is to melt the locktite at the stud base - grab that sucker with the vice grips and attempt to twist off. If that doesn;t work - then resolve yourself to a complete case split and rebuild. (and I would send to a machine shop that specializes in Porsche - like Ollies, EBS, Etc...

Just my .02 cents.

Weld a nut on the stud and remove with a wrench. You said you already have an oxy-actyline kit. I'm a big fan of not splitting the case if you don't have to. I'd say you could remove the one case bolt that is in your way without splitting the case.

-Andy