Aurel`s engine rebuild thread

[iangray100]

thanks ,
I'm flying to NJ from the UK on Sunday so I will try and pick one up...just for "Garage tool Stock" ;-)

I can see you having some intresting times.....I did with my 964 rebuild. Posted on Pelican as well, and should be in the Jan 08 edition of "Total 911 magazine"...a Pelican sponsor as well.

Ian

[jsveb]

Hi
I don't know if this has been mentioned in any other threads -propably has...
After I changed the exhaust on my 911 I realized broken studs is not that big of a deal, sounds corny i know, but I read about something called EDM (electrical discharge machine) in Waynes 101 projects book, accidently broke a stud an couldn't get it out, tried it all from heat to snap-on. I consulted the 101 again and started a search on the EDM stuff. coincidently my farther worked at Vestas (the windmills) and they had this machine. we removed the broken stud in about 30 minutes, no sweat at all. We had never tried it before, just borroved the equipment. The thing is the EDM itself is not that common so it may require at little search. Hope the story is OK (no thread steeling) best of luck with your rebuild, I will be joining you soon.
jesper

[911pcars]

It would be immensely more convenient if an EDM setup could work on the car .... and upside down. The inconvenient part of stud removal with EDM is the process of removing the cylinder head just to access the stud.

Sherwood

[efhughes3]

Originally Posted by 911pcars

It would be immensely more convenient if an EDM setup could work on the car .... and upside down. The inconvenient part of stud removal with EDM is the process of removing the cylinder head just to access the stud.

Sherwood

Exactly. The main reason studs are such a big deal is that they often break when the engine is in the car. When the heads are off anyway, they aren't that big of a deal.

[OldTee]

Aurel,
U have a private msg.

[Aurel]

Update: I borrowed a bore gauge from work, and I measured my cylinder diameters at 30 mm from the upper edge, as Wayne book says.

Here are the values:

Cyl# d(mm)
1 95.0722
2 95.0468
3 95.0595
4 95.0468
5 95.0468
6 95.0341

They all have less than 0.08 mm wear, so I can reuse them, right?
The ring groove clearances on the pistons were all within specs, even with the old rings. What else should I measure?

Aurel

[911pcars]

You could measure each cylinder 90º from your first measurement. That would provide an out-of-round measurement to compare with spec.

You could measure the bottom of the cylinder in a non-wear area to establish the unworn bore dimension, then compare with your top measurements. That would provide a taper spec.

Use an outside micrometer to measure the piston OD (about 30mm above the bottom of the skirt). That would provide the piston diameter and a piston-to-cylinder clearance spec when that dimension is subtracted from the cylinder bore measurement.

Same with piston pin bore and OD.

Sherwood

[hcoles]

0.08mm seems like a lot... isn't that something like 0.003" what is the spec.?

[jsveb]

Hi
thats's the good thing about it. The EDM was a portable system. Did it with the engine in the car - Upside down...
Regards
Jesper

[Aurel]

Some pictures: I got my renewed heads from Bob, he did a beautiful job. I repainted my fan shroud, sand blasted exhaust, shiny heat exchangers, rebuilt 915...things are shaping up.





Aurel

[911 tweaks]

any update on progrress?
I hope all is going well... my guess a delay was/is being encountered...?
Bob

[Aurel]

Garage is cold, but progress has been good. I sealed the long block, got my camshafts back reground to DC15 profile. Next is chain boxes, cam timing, reassembling the rockers. I still have to order the `piece of mind` chain tensionner update from our host and I`ll have all the parts I need. I decided not to split the case. Delay is mostly waiting to see how my tax return will look like...





Aurel

[Aurel]

For memo, here is the list of all upgrades done once it will be finished:

- All lower headstuds replaced with factory stainless steel.
- Heads professionally rebuilt.
- Gearbox professionally rebuilt.
- New rings and scotch brite honed Alusils that were in specs.
- Camshaft renewed to DC15 profile.
- Camshaft oil restrictors.
- Rocker shafts RSR seals
- New chains, ramps.
- Updated idler arms.
- Hydraulic chain tensionners.
- Replace cracked fan housing.

Then, and only if all works well (good rings seating, no oil leaks...), I may treat her with SSI heat exchangers.

Aurel

[iangray100]

I would have split the cases...you have put a lot of effort in and its minimal to go the next step...I heard of one engine 964 ...rebuilt like yours, 4K later the bottom bearings went ...a right off. I brough some of the parts for my rebuild.

I thought I might do what you did..see my thread as I went the whole way. Peace of mind.

Ian

[angelny911]

signing on seems like a great thread on info ...thanks Angel

[m_wuebben]

Would an oil analysis ahead of time be able to tell you if you have problems with the mains or layshaft bearings?? Cheers, Mike.

[Aurel]

Reporting progress: Cam timing is done, details here: Cam timing & valve-piston clearance
Carrera tensioners installed, rockers with RSR seals, valve gap set,
Long block is sealed, I am still looking for a replacement fan housing and few minor parts. Maybe one more month to go at my very leisurely pace...





Aurel

[efhughes3]

Looking good!

[Aurel]

I put the exhaust back on tonight. No SSIs before she proves she deserves it...



Aurel

[MBEngineering]

HI Aurel
I see you have fitted the exhaust with the engine upside down, I only hope there was no loose carbon in the ports and the exhaust was clean in side as it is out side, speaking from experience and I only fitted the exhaust like that the once, the loose carbon fell in to the exhaust ports and in to the engine giving it a miss fire on start up with carbon on a valve seat, the engine had to be striped and the valve/seat sorted, and I never fit the exhaust like that now, only 90deg and push it on , no hammering to make it fit, just in case.
I hope your is OK and not a prob' with the amount of work and effort you have put in to it .

regards mike