Darn circlips...
 

I spent the 4 hours today trying to insert a new circlip into my new JE piston without any luck :mad:

For the life of me, I couldn't even compress it enough to fit into the hole and this is on the bench.

I consulted with my mechanic and others who had done it to no avail. I'm almost ready to throw in the towel & send it to my mechanic. But is there any trick I can use?

thanks...

P.S. Yes - I also got coldfeet reading catca's incident with 10 stitches...

JE could do the entire world a favor by supplying a tool and instructions.
I notched a flat blade screw driver to catch the ring and press it into place.
JE should also supply at least one extra to replace the one that goes flying into space, never to be seen on earth again.
Jerry, are you listening. Jerry works at JE.
Seems to be a rite of passage.

Take a look at Cacta's thread. There is a picture of the tool I made to insert the clips. If you have grinder you can make one. Doesn't take to long and made inserting the clips safe and fast.

Here are some pics of the tools. I got pi$$ed when I had to go and get stitches. With this tool it took about 20sec for each clip. It was a piece of cake, no pain, easy to use. You put the clip in the tool on the bench and then drive it into the piston with driver portion. Real easy.

Here is Mike's

http://forums.pelicanparts.com/uploa...1149056759.jpg

Here is the one I used that Mike J made for his 993 rebuild. I had to modify it slightly to clear the JE crown and skirt. Worked great.

http://forums.pelicanparts.com/uploa...1149056815.jpg

The extension on the brass one I used fits inside the wristpin to center the tool on the piston.

Cheers

Jeff, how did you make the tool wih the tapered dimensions?

Doug, I did make a flat screwdriver with a notch. I just couldn't compress the ring enough to fit thru the hole :(

Mike / Jeff, in fact, would you be willing to rent/sell your tool?

I agree - for all their fanfare - I would think JE would supply a tool for the clips - probably one of the hardest parts of my entire rebuild.

I don't "own" the one I used. But MIke J and I are going to hack around on the lathe soon and make some more. He made this one on his lathe. However, I think the other Mike (daimond Blue) made his with hand tools.

Cheers

Those tools are cool. Wish I had them.

However what I use is the slotted screwdriver and duct tape.

I wrap the duct tape around my thumb to aid in pushing it in. Push it in open end first REALLY hard (tape keeps your thumb from splitting). Then push it the rest of the way with a slotted screwdriver... DO a search on "circlip" and you'll see some of the solutions...

Try this method:

http://forums.pelicanparts.com/showthread.php?s=&threadid=172957&highlight=JE+cir clips

Don't forget to cover the cylinder holes with rags or plastic wrap as you install the circlips.

I daringly (foolishly?) thought I didn't need to do that, having successfully installed circlips many times in the past without incident. During assembly last summer, one circlip went "piiiiing thwick" into the engine. Or so it seemed. I rotated the engine around on the stand a bunch of times, removed what covers I could, peered in with mirrors, probed with magnets, listened for the clip moving around, and pulled all the tricks I could muster. Nothing. I began to wonder if the circlip actually went into the engine. I spent a good hour fiddling, during which I considered the depressing consequences of a forced disassembly to retrieve the wayward clip. I was haunted by the even more depressing thought that maybe the clip wasn't actually in the engine, that the disassembly would be for naught, and that the circlip would be found years later behind the toolbox. Just as I was about to give up and start unscrewing the case bolts, the engine coughed up the circlip and dropped it to the floor. Whew!

Be careful out there...

Another benefit of using the tool is it is really hard to not have the clip go into the piston and fly off into space or the motor. It is nearly fool proof.

Cheers

Jeff, let me know when you're making them for public consumption... Now that J&E's are actually making good pistons for Porsches (not like the old days of needing 7 thou of clearance) I'm using them more often...

I would send the one I have to be used. Let me know.

Will do Chris, we are going to mess around a little to try to make it even better. I will send one your way as soon as we have them done.(it may be a while)

I never measured the ID of the hole in the JE pin, my mistake. Can someone out there do that for me?

Cheers

Yeah, I used a non-notched scewdriver (can you say nervous?) and my index finger. Actually, finagled a great method but, I think I have some permanent nerve damage in my left index finger. I'll try duct tape next time - GREAT idea! Screw the fancy tools http://www.pelicanparts.com/support/smileys/grenade.gif