Bring it over. We will fire up the welder when you are ready. You can borrow the trailer if the car is not drivable.

Jay,
Looking good - you will definitely be on the road before I am. Question - I have an oil tank and brass front cooler that I picked up used from Pelican and was also thinking of sending them to Pacific Oil Cooler to have them cleaned, but do you know of a local shop that does this type of work? I would also like to get the gas tank cleaned out as long as it is out of the car.

Frank

Unfortunately, no. I called every radiator shop in Austin and noone wanted to mess with it. You might check with Rich Johnson (a914guy@aol.com) as he offers the service for 914/6 conversions....

showtime
 

Well, it's almost showtime. After 18 months of having the nose pointing out, I turned her around and put her a$$ in the air to have a look at the mount.

http://forums.pelicanparts.com/uploa...1255383802.jpg

Now, I can't seem to work out how the mount will go in around the master cylinder. I guess I'll email Rich to find out....

http://forums.pelicanparts.com/uploa...1255383882.jpg
http://forums.pelicanparts.com/uploa...1255383901.jpg
http://forums.pelicanparts.com/uploa...1255383917.jpg

That is the proportioning valve. Round file it and put in an adjustable prop. valve off to the left.
I can post a pic of my set-up later, if you like.

JP, ya had me smiling till that 4 cylinder bit.:(

Thanks JP. Did you have to grind off the mounting plate for the proportioning valve, or does the mount fit around it after the valve has been appropriately stored in the round file?? Thanks!!

Mine is(was) a late model 914 with the porp. valve mounted off to the left. .....still in the way tho, IIRC.....that was 12 years back. I was able to adapt the original mount for the new jobbie. I'll get you a pic later this afternoon (I'm at wurk) and you can finger it out from there.
You'll probably have to run 2 new brake lines to the claipers.

JPIII - I don't want to hijack Jay's thread. (Wow there are a lot of J- names here). Don't be too disappointed - Its a healthy 4-cyl motor. Here is the description of the new project.

http://forums.pelicanparts.com/porsche-911-technical-forum/500848-time-new-project-2010-grm-challenge-car.html

Yeah,well, I was here first.:D

http://forums.pelicanparts.com/uploa...1255474988.jpg


Here's your pic, Jay. .....

Mount is in...
 

OK Guys,
The mount is IN!! http://forums.pelicanparts.com/support/smileys/wat6.gif I'll be sending a PM to check your availability for the weld-in, Jamie!! Now, if I can only muster the patience to attack the little bit of rust in the longs before I stuff the new motor in.... Here ya go! Just a touch of brake plumbing, and a grand total of six inches of good weld, and the motor is ready to go in!!

http://forums.pelicanparts.com/uploa...1256577686.jpg

Marching on....
 

Where in the world would I be without Jamie Novak! http://forums.pelicanparts.com/support/smileys/wat6.gif Jamie graciously loaded up his welding stuff and came by the house yesterday. After a few minor alterations, the mount was in, prepped, and ready to be welded.

So, Get ready....

http://forums.pelicanparts.com/uploa...1257127587.jpg

Get set.....

http://forums.pelicanparts.com/uploa...1257127609.jpg

Go!!!!!!!!

http://forums.pelicanparts.com/uploa...1257127631.jpg

Now, the mount is in! Just a bit of cleanup, repaint, re-route the brake line, and the motor is going in! Thanks, Jamie!

--Jaybird

firewall goop
 

Here's a sure-fire way to deal with removing the firewall adhesive/tar paper--wire wheel the beotch down to the metal!!!

http://forums.pelicanparts.com/uploa...1257194487.jpg

more to follow...:cool:

jaibird840 very nice job, i wonder why you did not used the B&B headers?

Diego,

The B&B headers would not fit for my application. Several people also believed that the 1 5/8" tubes were too large. Thanks!

The engine is in!!!
 

After waiting a week for a metric brake line tee to come in the mail, the day arrived. I installed the tee and checked the brakes--no leaks (still need to be bled). Once I hit that point, there was no sense in waiting to stuff the engine in. One man, a floor jack, two hours, and a bunch of determination..... IT'S IN!!!

http://forums.pelicanparts.com/uploa...1258576121.jpg

http://forums.pelicanparts.com/uploa...1258576135.jpg

Now it finally looks right again when it's off jackstands for the first time in eighteen months.... Just a few items left to sort out, and then fire it up!

http://forums.pelicanparts.com/uploa...1258576207.jpg


Almost home....

Well, it's been almost a year since my last post. Hard to believe.... Short project funds, and trying to sort the oiling system have consumed 11 months. With that said, everything is in the car and hooked up (except shift rod and throttle cable). I'm showing good oil pressure by the idiot light and VDO gauge while cranking, so that's a relief. However, I cannot seem to get the car to fire. Given that I've gotten a few loud backfires through the velocity stacks, I think my timing is off. I'm concerned now that my distributor may not have been installed correctly. I'm getting fuel (pump jets, anyway) and spark from the coil per MSD's instructions. So anyway, I now think I need to go in and verify that I have the dizzy indexed correctly. So, In order to locate TDC for Cylinder #1, it should be the point where both the intake and exhaust rockers have slack in them, right. Is there any other point in the cycle where both valves would be completely closed? My next idea is to verify that #1 is at TDC via the previous method, and then re-index my dizzy. Any thoughts would be appreciated. I'm ready to hear Weber music!!!!!!!

Do you have access to your timing mark? I assume so, set it to TDC and both intake and exhaust rockers should be free, if not then your on #4. I'd static time it for start up. My 2.7 CIS times at 3 BTDC without vacuum. With points watch / listen for the point to spark, with pertronix use a test light on the dist wire to - coil.

OK, I corrected the timing issue by re-indexing the distributor. I have the timing set at TDC for now... the car will now somewhat fire, and I can manage a stumbling run-on at about 800-1000 rpm if I pump the linkage like a madman to activate the pump jets. It will run in this fashion as long as I'm feeding it raw fuel. As soon as I stop pumping the jets, it dies. So, what's next in the process?

It appears that there is some disparity in the amount of fuel being sent by the carbs. I pulled the #3 plug and it looked new. I pulled #5, and here's a pic. It doesn't smell like raw fuel, but doesn't look so good. there is also some raw fuel spilling from the exhaust when I crank it....

http://forums.pelicanparts.com/uploa...1286560266.jpg


what next??? :confused:

Finally.....success!!!
 

After two years, five months and four days.... she's running! Here is the video of the cam break-in. As it turns out, the timing was way out from static to dynamic. I ended up having to re-index the distributor by one tooth, and then make several index marks on the flywheel with soapstone (it's a 914, you can't see the pulley) to figure out which way I needed to go it was off so far. When I finally got the timing light to hit the mark at 10 deg. BTDC, she fired right up! All the initial signs were good, oil pressure was at 20psi, and I could see the oil rapidly reentering the front tank. No leaks (Thanks Wayne!) and no major malfunctions. Here is a video of the Weber music as it was made.


<object width="425" height="344"><param name="movie" value="http://www.youtube.com/v/HelewSaF6ak?hl=en&fs=1"></param><param name="allowFullScreen" value="true"></param><param name="allowscriptaccess" value="always"></param><embed src="http://www.youtube.com/v/HelewSaF6ak?hl=en&fs=1" type="application/x-shockwave-flash" allowscriptaccess="always" allowfullscreen="true" width="425" height="344"></embed></object>

Although I still have a long way to go to get her on the road again, I feel like I'm over the hump. So with that said.....

I wish to express my sincerest and most heartfelt appreciation to the following people:

Jamie Novak: You, sir...are the king! Without Jamie's constant support and willingness to loan tools, load up his welder, calculate my compression ratio, loan me parts to try out and fit, and generally listen to my ranting for almost three years, this project DEFINITELY would have stalled out long ago without your selfless willingness to help another lost soul out. I now understand the debt you feel to Warren. Good Karma on you and your family for years to come! We'll be on the road soon.....SmileWavy

Craig Garrett (G2 Racing): Craig went the extra mile to make sure that my machine work on the 2.7 case was nothing less than spectacular. His service beyond the sale is top-notch. He went waaaay above and beyond what I paid him for (dirt cheap, too!) and I highly recommend him for any machine work, especially heads. Thanks Craig!

The list from here on is long and deep: Steve at Rennsport for his willingness to share experience and advice without a penny earned to keep his doors open--good Karma to you, too! Dick Shift, you too... Mark W., thanks for the inspiration and encouragement. Redbeard gets props for doing the gearbox rebuild clinic and using my tranny as the model. I'm certain that I'm still leaving out a long list of people who are very deserving of my thanks, but I'll make it public when I remember.

Now to sort out about two dozen little details (including what I think is a bad alternator, weber tuning, etc.)

At last...... Weber Music.

--Jaybird :)

Congratulations - it must be a wonderful feeling that I hope to enjoy as well sometime soon (my 911 been apart a bit longer than your 914).

If you need any jets, emulsion tubes or a flow meter for tuning your Webers, let me know. I don't recall exactly what I have at the moment, but I know I ended up with some extras after tuning mine.

Frank

There is nothing like the phone call noting the verbal elation when the car is running and the owner is beaming with pride.

Congratulations Jay! you earned this one.

Now get some seats in that car so we can break the motor in properly. :) FM1826 is begging for some high-rpm runs.

Jaybird,
Nice work, one of the best posts I've read. Definitely one for my archive. Beyond waynes book was there any other significant books you worked with.

Ed,
Wayne's book was the basis for my rebuild. I believe I consulted Bruce Anderson's book some, but everything I needed was found in Wayne's book, and here on the board. It's a hair-raising proposition to have your first motor build be done "by the book" without a tutor watching over your shoulder. So far, so good with mine. I'm working out tons of little gremlins, but overall the motor appears to be pretty sound, and makes tons of power. I have maybe 150-200 miles on it so far, but I've progressed to the point that I can take it out and just drive it without feeling like I have to watch the gauges constantly and listen for every little hiccup it makes. I'll be in much better shape after I get my first dyno runs done, which will hopefully be over the winter. Every time I drive it, the grin factor from hearing the motor I built singing down the road is almost overwhelming. I'm already starting to dream about my next motor build.

Congratulations as well!
10 deg. BTDC is a bit much for an air cooled engine. Keep an eye on the temp. And an open ear for the sounds of preingition.

Great Write Up!
 

Jay, you're an inspiration! I've been without a Porsche for 20 years and am looking now while I wait for my kids to finish college and free some cash! I've built vintage 2 stroke mx bike motors, so it's tempting to find a project and do an engine rebuild like you did. Not sure I have the patience to go through 2 year rebuild tho! Great job and enjoy!!

Tom Viers
Cape Girardeau, MO

Jaybird,
Congrats and I can share that overwhelming feeling with you. I got my engine running again on Monday after only 8 months and cannot describe the feeling of hearing her run in at 2000rpm. When the wife and kids came out to the garage on hearing the engine I am not sure if the small tear in my eye was from pride or the break in smoke she was making. However again hearty congrats it is great to have something you built by yourself run...

Here's a clip for all of you who helped and advised on the rebuild. A thousand and one thanks to all of you! SmileWavy

<object width="425" height="344"><param name="movie" value="http://www.youtube.com/v/U_APZLA7Lm0?hl=en&fs=1"></param><param name="allowFullScreen" value="true"></param><param name="allowscriptaccess" value="always"></param><embed src="http://www.youtube.com/v/U_APZLA7Lm0?hl=en&fs=1" type="application/x-shockwave-flash" allowscriptaccess="always" allowfullscreen="true" width="425" height="344"></embed></object>

Nice. Well Done. Congrats!

Great job. I loved your camera persons comments at the end of the video LOL!

Ow your wife told you.....