Pictures of my rebuild efforts

[squidmarks]

Some of you may have seen my posts about my rebuild project. I purchased a rather distressed '82SC in Dec/06. When I got it, the engine/tranny was out (PO took it to a mechanic who told him it needed a rebuild, PO didn't want to pay, so mechanic gave it back to him in pieces). I plan to do a complete restore. This winter I've been working my way thru the engine and transmission. At this point, the engine has been completely disassembled, cleaned and parts are back from machining - I will be starting reassembly this week. While I've been waiting for parts back from the machinist (Henry Schmidt did a very nice job on the heads), I rebuilt the CIS system, distributor, alternator, starter and transmission.

Here's a link to my photo blog that shows my progress.

http://picasaweb.google.com/geoff.gerhardt

This site is organized into sections and shows all photos taken during disassembly and reassembly. If anyone is doing a similar rebuild, you might find it useful if you forget how something is supposed to look.

I'll post a note to this thread every once in awhile when I make some progress.

Thanks to all of you for helping me thus far in this rebuild. I'm sure I'll have a lot more questions as I begin the process of reassembling the engine. Once the engine is back together, I'll set it aside and get started stripping the body.

Geoff

[SP2]

Wow, awsome work. Please post a video of the start-up. Is this the first time you have done this? If so, strong work man!

[squidmarks]

Thanks James. The startup is a long way off. I expect to wrap up the rebuilt engine and transmission and sit it in a corner while I tackle the body. I imagine it will take me a year to get it stripped down and painted. Having fun, tho. I haven't rebuilt a 911 before - I've mostly worked on motorcycles in the past. Until ~November last year, I wasn't really "into" 911's. I just got it into my head that it would be a good project - I was right.

Geoff

Geoff

[Porsche_monkey]

How did you get the tranny case that clean?

[squidmarks]

Regarding the transmission case cleaning, I started with engine cleaner and a high-pressure washer to get the major crap off before taking it apart. After separating the cases, I cleaned the grime off in my parts washer. Because of the deep crevasses, I ended up using a pick to get the oil grime out of the little corners. After all the oily crap was removed, it was media blasted (glass beads) then washed with copious amounts of soap and hot water and finally brake cleaner to ensure all media was removed from the passages.

Getting the cases clean turned into a bigger job that I thought it would be, but they turned out pretty nice. It will be a shame to hang it under the car where it will get filthy again, tho.

Geoff

[squidmarks]

Here's another update. Just completed assembly of the short block today (Chapter 5, Sections 1-3 of Wayne's book).

Click here to go to the photo blog

Everything went swimmingly. I was sweating a bit as I was coming close to the 45 min time that Wayne stresses a couple time in the book is the maximum time you have from application of the Locktite 574 case sealer until the last bolt is torqued. I think that time might be very conservative, tho, as about 2hrs after I had applied the Locktite, I was tossing the brush I used to spread it, and noticed that it was still very liquid.

You'll notice that my cases are not as clean as, say, my transmission cases. I did not bead blast the engine cases as I didn't want to spend 2 months trying to get every last bead out of each nook and crany. The transmission cases are very wide open with easy-to-clean passages. I was able to get the engine cases very clean (in a sanitary sense) and free of oil and debris, but I did not go the next step of polishing them and getting all the surface oxidation and stains off that would have made them cosmetically better looking.

Now its time for the heads...

Geoff

[turbobrat930]

[QUOTE. I was sweating a bit as I was coming close to the 45 min time that Wayne stresses a couple time in the book is the maximum time you have from application of the Locktite 574 case sealer until the last bolt is torqued. I think that time might be very conservative, tho, as about 2hrs after I had applied the Locktite, I was tossing the brush I used to spread it, and noticed that it was still very liquid.


Geoff [/B][/QUOTE] \\

Geoff, The locktite 574 wil stay liquid for years on the brush. The locktite 574 is an anaerobic sealant...meaning, it only cures in the presence of no air. The time is VERY critical, and will start to harden shortly after the case halves come together. I was told 10 minutes as the working time before it sets up, and the case bolts should be torqued during that 10 minute period as well. Now, I dont know if that 10 minutes is a conservative figure or not, BUT I will say that the sooner the case is torqued, the better.

[shbop]

Geoff, What type of cylinders did you have there? Thanks

[squidmarks]

The cylinders that were in the engine were Alusil. Several measured out of spec and one was severely scored. I sold them to someone who thought they might be able to find a good one or two in the set.

I purchased another set of Alusils from Tom Butler who has quite a collection that he has properly reconditioned and matched piston/cylinder sets.

One thing that I just came across as I was checking the deck height of my pistons using the techniqued outlined in Wayne's book - i.e. putting a couple bits of plumber's solder at the edges of the cylinder, assembling the head then turning the crank past TDC to crush the solder bits. On the first one I checked, the deck height is measuring 1.8-2.0mm. I am using the copper shims that came with my gasket kit. I just checked them and found that they are 0.050mm thick. Like a fool, I left the copper shims on my original p/c set that I sold. They were thinner, probably 0.025mm. Looks like I need to find a 0.025mm set of shims.

Geoff

[klaucke]

Looks great Geoff! So much cleaner than when I saw the pieces.

[shbop]

Thank you Geoff. Your project looks great.