3.2 build progress-it looks like an engine again...

[efhughes3]

Got the heads on the other side today. I was a little quicker than the other side-particularly since I forgot to put the cooling tin on. I removed the entire head assembly to remove the tubes so I could get the tin on. Bonehead mistake.

Oops, forgot something:



Fixed-no harm, no foul:



Sporting some of the goodies, I can't wait until everything goes on for real:





That'll be it for a few days. Off to SoCal tomorrow to look at houses. Next week: CAM TIMING

[gigem75]

cam timing, piece of cake

looks great!

[efhughes3]

Originally Posted by gigem75

cam timing, piece of cake

looks great!

I hope so, it is just one of those unknowns, the last "big hurdle"....I cleaned all of my cam tensioners, idlers, sprockets and such in preparation for next week. After that, it seems like the main thing is remembering to put all of the right stuff on in the right order. I sure have a lot of parts still to go back on. I hope I took enough pictures!

It wasn't so long ago that I thought simply taking the engine out was a big deal...

[Brother]

I really like the color choice. What color is your shroud?

Is there another thread with the particulars of the build? I just started thinking 911's again.

[dtw]

Cam timing: grossly over-hyped. If you 'get' what's going on, you'll have no problem. Looking very nice so far, good work. All downhill from here!

[efhughes3]

I went to Hobby Lobby the other day to get a Testor's paint pen to do the red on the valve covers. They also had blank inkjet decal paper....

I downloaded the Porsche font and printed out a PORSCHE decal to go on the fan housing strap. It is the same titanium ceramic coating as the fan, and I think it needs a little dressing up. While I was at it, I printed another decal to match, we'll see if it can go somewhere under the bonnet.

[efhughes3]

Originally Posted by Brother

I really like the color choice. What color is your shroud?

Is there another thread with the particulars of the build? I just started thinking 911's again.

Hi Paul, it's about time you came to your senses....the shroud is black. I've been all over the map on posting, I should've stuck with one thread. Here are the quick details:

Case cleaned and checked for bore, oil galleys, squirters, etc.
Crank mag'd, cleaned and micropolished
Heads rebuilt, new exh valves, twin plugged , racing springs, Ti retainers
P's and C's inspected, and are well within spec, being reused
Rods rebushed and resized
Rockers rebushed and refurbed
Cams ground to DR Camshafts DC19 profile
Cam towers inspected, replumbed and cleaned
New main, rod and intermediate bearings
ARP rod bolts
Supertec head studs
Wrightwood Racing viton gasket set
Rebuilt injectors
Cleaned, leak tested & repaired engine-mounted oil cooler
New: rings, chains, ramps, oil return tubes, case hardware, oil relief valve hardware, rocker hardware & seals, alternator, cam lines, etc, etc
Misc Cad plating and powder coating

My clutch and flywheel are only about 2 years/5000 miles old, so I'm working with them The total of all of this will be close to what the car cost me originally.

[zbph10]

NICE JOB, looks very familiar. I was in the same place you were last winter.
Here's mine completed



Cam timing is a piece of cake once you get your arms around it and have the proper tools. Do you have the Bentley manuals?

I'm surprised to hear you have as much into your motor as the car originally, I think I had about $4K into the rebuild.

My clutch was fairly new but I still replaced the TO and pilot bearings and updated to the new clutch release fork

Good luck

[efhughes3]

I've got all the proper tools as well as Bentley, Factory, Wayne's book, etc. Its all in my mind. I know that once I get into it, the project isn't beyond my capability.

I'm not sure what all you did for $4K? Other than reusing my pistons and cylinders, I've replaced or rehabbed about everything in my engine. Going to Aasco springs, Ti retainers, all new head stud hardware, ARP rod bolts and machining can add up pretty quickly. I'd say $4K is on the low end of costs I've seen, and mine's probably a bit more than the average.

It's all relative, I bought my car for a very reasonable cost.

[Jeff Alton]

Looking good Ed! I have forgot those same pesky black parts before too!!

I like the decal you made! Cool.

Cheers

[Brother]

Nice. So you are sticking with the stock compression ratio or are you bumping it up a bit? New chip?

What precipitated the rebuild - breakage or boredom?

[efhughes3]

Stock compression, I'm sticking with my Steve W chip, he thinks I'm ok for now. When we get to California next year, I'm looking at having him do a custom setup.

The reason? Hmmm....I think it was the nut behind the wheel. I was coming out of Richochet @ MSR-I was passing someone, and had a Cup Car on my tail-pulled her into 2nd instead of 4th. The exhaust valves protested in anger.

[911 tweaks]

Hi Ed, YOUR ENGINE LOOKS GREAT!!!!!!!
I am sure you posted this, however, what is the finish~process you did on the fan ring and top alum valve covers?
Thanks, Bob

[Brother]

Well, well. I'm moving to California next summer too. I'll be up north of Sacramento.

I bet that missed shift was a serious "OH $hit" moment.

How do you expect the cam profile to change the driving characteristics?

[tsiegwart]

Ed, thanks for the thread!! I've got a 3.2 that someday I'll do a rebuild on myself.

I have a question for you.

I've heard that dissasembling and re-assembling the top end and FI system are "%80 of the effort" (ie, you might as well split the case if you do a top end job). Did you find that to be the case? How hard was re-assemplying the crank, intermediate shaft and the case?

Thanks again.

[efhughes3]

Originally Posted by 911 tweaks

Hi Ed, YOUR ENGINE LOOKS GREAT!!!!!!!
I am sure you posted this, however, what is the finish~process you did on the fan ring and top alum valve covers?
Thanks, Bob

It is a ceramic coating recommended for Magnesium by my powder coater. I did the valve covers to match the fan.

Originally Posted by Brother

Well, well. I'm moving to California next summer too. I'll be up north of Sacramento.

I bet that missed shift was a serious "OH $hit" moment.

How do you expect the cam profile to change the driving characteristics?

More power? A little better from mid into top end...

Originally Posted by tsiegwart

Ed, thanks for the thread!! I've got a 3.2 that someday I'll do a rebuild on myself.

I have a question for you.

I've heard that dissasembling and re-assembling the top end and FI system are "%80 of the effort" (ie, you might as well split the case if you do a top end job). Did you find that to be the case? How hard was re-assemplying the crank, intermediate shaft and the case?

Thanks again.

I'd say that the biggest stress in that area was the sealing of the case, but it wasn't that big of a deal. The rods, bearings and such were pretty simple. If I hadn't stretched rod bolts and had to open my bottom end, I think it would've been fine. But even at that, I think it would be crazy to tear down a 130K mile motor, spend several thousand $ on it, and not do the bottom end.

[efhughes3]

I chunked away at it today. I got the chain cases on, the cams lubed and in, and the timing chain sprockets on. Tomorrow is the "day of the cams". I'll time them, finally getting to use the tools Jeff Alton sent me in April or May...








Speaking of Jeff, he called it correctly when he noted I'll have to machine my LH lower valve cover a bit to clear the spark plug boot.




I also have to open up the casting on the RH chain box.

[BReyes]

Awesome- Being able to look behind the rebuild - back in the drivers seat!

Giving you some moral support for the cam timing!

[efhughes3]

Thanks Bernard! After a bit of a fight yesterday, I got the cams timed. See this thread for the details:

http://forums.pelicanparts.com/911-engine-rebuilding-forum/378452-stuck-cam-timing-issue-me.html#post3600411

It's really coming together now. I'm going to run and pick up a few more parts today, so that I'll have it all at my fingertips, based on progress this weekend:

Rebuilt Alternator, Spark Plugs, THREE oil filters, new fan belt, etc.

Plus, I'm going to go to Lowes and get a couple of 5/8 OD X 1/2 ID bronze bushings to make the safety collars for the pressure tensioners.

I'm going to take a day off today, and get back at it Friday:

1. Piston-Valve clearance check
2. Balance of rockers-install and adjust
3. Cam case covers-install
4. Install my freshly rebuilt oil cooler

This will give me a complete longblock for the first time in 7 months. Then, Saturday and Sunday comes the fun part of remembering how my injection went together, and installing it as well as shroud, exhaust, etc. We'll see how far I get.

[eapcpa]

Very nice work!! It feels great to get things together after a long time but you are really paying attention to details.