Making A Piston Clip Tool (Guerilla Method)
 

I was having an aweful time getting the piston clips in on my new JE 98mm coated 8:1 pistons. They have those terrible, heavy spring clips that don't want to bend for anything. I have installed similar ones on my last build but I recall those being less difficult. Maybe the shape of the piston skirt was different on those (95mm 11:1 compression) or maybe JE is just making them even harder:mad:

So after trying many of the methods described on other threads I was at my wits' end. So I went searching for materials to make my own tool...

...I went to the hardware store and bought some alu tube with a 20MM OD. I immediately found that the ID was too thin, so that I couldnt' get the circlip to get down inside that tube. It would close as it was inserted so that it couldnt compress any more.

So I went searching the house for anything other tube with an OD of 21MM and an ID as big as possible. I found Barbara's mop handle was exactly what I was looking for...so I stole it...

I then cut the handle off into a 4" section.

http://forums.pelicanparts.com/uploa...1212912605.jpg

I guess I shouldnt be posting incriminating pics...

Then I found that a 14MM socket has an OD just smaller than the ID of the ex-broomhandle.

http://forums.pelicanparts.com/uploa...1212912713.jpg

The experiment continued by using one of my notched screwdrivers (a failed experiment to try what worked for someone else on another thready) to force the clip down into the tube.

http://forums.pelicanparts.com/uploa...1212912828.jpg

Then I held the tube up against the wrist pin...


http://forums.pelicanparts.com/uploa...1212912922.jpg


Then I pushed the socket through the inside of the tube, which in turn forces the clip out and into its groove against the wrist pin. That smile tells the story of that sound when the clip "SNAPS" into place.

http://forums.pelicanparts.com/uploa...1212913103.jpg

Gratituous pic of the perfectbore cylinders and ceramic top/dry film lube sided JE pistons...

http://forums.pelicanparts.com/uploa...1212913191.jpg

http://forums.pelicanparts.com/uploa...1212913251.jpg

I hope that helps someone and doesnt offend anyone who sells tools to do the same...and don't tell Barbara.

necesity (sp) is the motherhod of invention !! Nice job ! Now you need to think of how to dodge the wife when she asks if you have seen her broom... better go buy a replacement one soon...
LOL
Nice job and creative... tell us more about what you are building

Bob

Your 1000th post Bob!

I actually came upstairs with arms up and declared myself the smartest man on earth loudly and repeatedly. The dog looked at me weird.

This is a 3.2 supercharged engine for the race car with a goal of 450 rwhp. 3.0 case and heads, DR20 cams, autorotor supercharger at ~15 psi, air-air intercooler, shortened G50, adaptronic ECU, twin-plugged wasted spark ignition. 3.2 intake with 80MM throttle body. Other goodies too...

No new mop needed. Put the rubber handle back on - I see it in the picture - she'll just think see's getting TALLER - I don't know any women who would worry about THAT!

The safety glasses are a good example to all of us.

thx John on the posts... I guess I have been around here for a while... maybe too long ;-)

nice to hear about the build... do you have a post on it so we can follow ?

good pt on the glasses too by notmytarga !!

Best of luck John with the build there !! It looks like she is gonna be a doosie there !!

Bob

I had to pause progress due to shipping delays on head nuts, finally got them this week (took 6 weeks!?!). Installed the remaining clips with the new tool, again it never took more than 2 tries to pop the clips in.

Should have the cam towers on and timing done today, in between naps. I've got the king of all colds, just in time for a sunny 3-day weekend!

While I was waiting for the head nuts I was able to install the new fuel system with a cell and Aeromotive pump in the bottom half of the old gas tank. When its painted up I'll share it, pretty proud of how that came out too.

thanks for this John

years later lol

glenn

Why doesn't the Porsche community use the standard circlips like pictured here?

The Porsche original circlips are ridiculous to work with!

http://forums.pelicanparts.com/uploa...1396148179.jpg

The JE clip issue is specific the 911 application. Their other applications that I've worked with use a smaller diameter wire for the clips and are reasonable to work with. I theorize that perhaps the 911 application is more litigious should a failure occur so they went overkill after being burned by a few owners who blamed the clips. Many sarcastic thanks to those engine builders / owners for ruining it for the rest of us. ;)

Remember this from above?

http://forums.pelicanparts.com/uploa...1212913191.jpg

This is what they turned into...

http://forums.pelicanparts.com/uploa...1396193536.jpg

6 engine builds later and I'm still using that broom handle piece and socket to install clips.

JohnJL,
Nice application of guerilla tactics. Now create a tool from the remaining parts of the mop to extract the circlips. :)

Sherwood

John thanks for the point. I will be needing that soon.

Project list:

Section of metal broom handle
14 mm Socket
Flat tip screwdriver with V groove

I have all on hand I will build tomorrow..

John