Help Needed - 3.2SS Rebuild

[alphie]

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.

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

[kenikh]

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

[YTNUKLR]

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

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

[alphie]

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

Any vice grip suggestions???

[JeremyD]

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

Something like this


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.

[Eagledriver]

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