My 3.0 to 3.2ss Rebuild

[alphie]

After countless months researching, planning, cleaning, ordering, buying,etc, yesterday I finally sealed the case on my '79 3.0SC to 3.2SS rebuild.

The original engine had 88k miles on it, running quite well. I caught the upgrade bug and over a 10 month period I purchased:

- good used set of Mahle Max Moritz 98 9.8:1 pistons and cylinders from fellow pelican Alan in England
- DC20 cams from Jeff Alton with reconditioned rockers (all done by John Dougherty
- TBitz EFI which I installed prior to the rebuild


My plan was to do a top-end rebuild but after tearing down the motor I found a broken exhaust side head stud. It was broken close to the case, I couldn't remove it and I ended up splitting the case and sending it to Lance of Hayward Performance in British Columbia. Lance handled a worse situation for Jeff so I felt comfortable even though I had to ship the case across the country. Lance was fantastic, he removed the stud and shaved 6 thou' off the cylinder spigots.

First stop, cleaning. I think I spent over 30 hours cleaning the case AFTER getting it jet washed by the machine shop.

Pics to follow...

[alphie]

First engine drop:



Obligatory sitting in engine bay shot:



My daughter and nephew assembling the engine stand:



Teardown begins:

[alphie]

Here's where I discover Alusil:



Working on the crank:

[alphie]

Case assembly:

[alphie]

For sealants I used threebond on the perimeter, 571 VERY LIGHTLY on the webs and curil on the flywheel seal:





Case sealed and next day head stud instal begins:



A pic of a 98mm P&C reconditioned by Henry of Supertec!

[DW SD]

Nice work!!

Doug

[Jeff Alton]

Looking really good. Your pic of the case half should be used for reference for others, that is what it should look like before assembly. Very nice! And for any one who needs expert machine service for their porsche, (heads, case etc) Lance is fantastic. He does all my machine work.

Cheers

[euro911sc]

Missed a spot...






... Kidding

Looks great!

-Michael

[alphie]

Thanks for the compliments!

Anyone attempting this for the first time I would highly recommend doing a dry-run putting the case halves together. That includes attaching, but not tightening, every single fastener, washer, stud, etc. And keep a count of every piece, perimeter bolts, washers, etc as you go along.

When it comes time to torquing, another tip is to mark off (on the case with a marker) each cash through bolt after you torque it, that ensures you torque each one.

Soon to follow are pics of the heads rebuilt by Henry with twin plugs, TI retainers and racing springs.

[lindemans]

I very much like the picture that shows how you supported the engine with the jack and the kart in between: superb idea !!