|
|
|
|
| Author |
|
|
Wer bremst verliert
Join Date: Jan 2005
Location: Toronto, Ontario
Posts: 4,767
|
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
 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.  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.  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.  Then I held the tube up against the wrist pin...  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.  Gratituous pic of the perfectbore cylinders and ceramic top/dry film lube sided JE pistons...   I hope that helps someone and doesnt offend anyone who sells tools to do the same...and don't tell Barbara.
__________________
2007 911 Turbo - Not a toy 1985 911 Cab - Wife's toy 1982 911 3.2 Indiash Rot Track Supercharged track toy 1978 911 3.0 Lichtbau toy "Gretchen" 1971 911 Targa S backroad toy Last edited by JohnJL; 06-08-2008 at 06:57 PM.. |
||
06-08-2008, 12:21 AM
|
|
|
Registered
Join Date: Apr 2006
Location: northeast
Posts: 4,530
|
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
__________________
I live for 911 tweaks... |
||
|
06-08-2008, 02:38 AM
|
|
|
Wer bremst verliert
Join Date: Jan 2005
Location: Toronto, Ontario
Posts: 4,767
|
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...
__________________
2007 911 Turbo - Not a toy 1985 911 Cab - Wife's toy 1982 911 3.2 Indiash Rot Track Supercharged track toy 1978 911 3.0 Lichtbau toy "Gretchen" 1971 911 Targa S backroad toy Last edited by JohnJL; 06-08-2008 at 02:56 AM.. |
||
|
06-08-2008, 02:52 AM
|
|
|
Registered
|
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.
__________________
75 911S Targa - Mine from 2001 until sold to Germany buyer 10/2016 <ALL DIY> Brakes/Wheels '01, Body/paint/restoration 7/04, Suspension 3/07 Engine rebuild - done 7/08 - added 28 tube cooler and SSIs - running strong. Ducktail painted. 2021 MachE, 2012 Outback, 2019 Crosstrek, 2018 Impreza wagon |
||
|
06-09-2008, 08:07 AM
|
|
|
Registered
Join Date: Apr 2006
Location: northeast
Posts: 4,530
|
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 live for 911 tweaks... |
||
|
06-09-2008, 08:46 AM
|
|
|
Wer bremst verliert
Join Date: Jan 2005
Location: Toronto, Ontario
Posts: 4,767
|
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.
__________________
2007 911 Turbo - Not a toy 1985 911 Cab - Wife's toy 1982 911 3.2 Indiash Rot Track Supercharged track toy 1978 911 3.0 Lichtbau toy "Gretchen" 1971 911 Targa S backroad toy |
||
|
08-01-2008, 05:38 PM
|
|
|
|
Enso
Join Date: Jan 2012
Location: Saskatoon Canada
Posts: 15
|
thanks for this John
years later lol glenn |
||
|
03-29-2014, 12:05 PM
|
|
|
Registered Loser
|
Why doesn't the Porsche community use the standard circlips like pictured here?
The Porsche original circlips are ridiculous to work with! 
__________________
Current Rides:: 1987 Red 911 Targa, 2007 R320 CDI, 2003 Red Dodge Ram Hemi, 1993 Beater Jeep Cherokee, Airbus A320 Gone but not forgotten: 1981 VW Scirocco S, 1989 Honda Accord Coupe LXI, F-16C (still my favorite vehicle!),MC-130P, C-130E, T-38, T-37, C150, C172, PA180 |
||
|
03-29-2014, 06:56 PM
|
|
|
Straight shooter
|
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.
__________________
“Of the value traps, the most widespread and pernicious is value rigidity. This is an inability to revalue what one sees because of commitment to previous values. In motorcycle maintenance, you MUST rediscover what you do as you go. Rigid values makes this impossible.” ― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values |
||
|
03-29-2014, 07:54 PM
|
|
|
Wer bremst verliert
Join Date: Jan 2005
Location: Toronto, Ontario
Posts: 4,767
|
Remember this from above?
This is what they turned into...  6 engine builds later and I'm still using that broom handle piece and socket to install clips.
__________________
2007 911 Turbo - Not a toy 1985 911 Cab - Wife's toy 1982 911 3.2 Indiash Rot Track Supercharged track toy 1978 911 3.0 Lichtbau toy "Gretchen" 1971 911 Targa S backroad toy |
||
|
03-30-2014, 07:32 AM
|
|
|
Registered
Join Date: Jul 2000
Location: So. Calif.
Posts: 19,910
|
JohnJL,
Nice application of guerilla tactics. Now create a tool from the remaining parts of the mop to extract the circlips.  Sherwood |
||
|
03-30-2014, 12:20 PM
|
|
|
Registered User
Join Date: Oct 2011
Location: Cayman Islands
Posts: 120
|
Quote:
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 |
||
|
03-30-2014, 12:53 PM
|
|
Targa
P911
