Terrified of doing my own rebuild

[ericheavner]

Ok, first let me say that I've been lurking on this board for a long time and reading tons of posts on engine rebuilds. I think this is my 1st post. My apologies for being rude over the years.

I have tinkered around with lawnmowers - replaced a cheapo tranny in a Craftsman and I'm currently rebuilding an Onan 18hp engine for my classic John Deere. This doesn't seem to be a big deal 'cause if I screw it up, it's only a lawnmower but it is horizontally opposed so I have this novice logic that I can do it.

Soooooooo, having said that, I must admit that I'm terrified of rebuilding my '82sc engine. I've read Wayne's books and it seems that a novice can really bugger up a good 3.0L.

Mine is starting to use more oil and I'd rather rebuild now than have something fail and encounter many $$$ more if I delay. I'd also like to get some more HP out of the ole 3.0 CIS and understand that there are a few 'safe' and reliable ways to do it.

How many of you have rebuilt an engine without any prior experience in engine stuff? Were you all successful? What would you have done differently? What would you do to increase the CIS HP?

Thanks!
Eric

[DSPTurtle]

Go for it. It is one of the most gratifying sounds in the world when you hear it fire up. Wayne's book is great. The toughest part is that first turn of the wrench. Getting the engine out of the car the first time is half the battle. Make sure you have a good digital camera and take way more photos then you think you will need. All angles, all zooms and every little nuance.
Oh yeah, biggest advice I would have is to get your Z-block and dial indicator before you pull everything apart. Hook it up and watch how the cams move the valves before you pull the chains off. It will make putting it back together that much easier.
And, get used to posting stupid questions here... the answers will come back to you with minimal harrassing

[jason442]

When I pulled my engine out of my 75 911 three months ago I could hardly sleep worrying about being able to put it back together. Before this my experience consisted of changing oil and taking apart my grandparents 59 international pickup out in the woods (tools in 5 gallon bucket) at 12 years old. I've had a lot of fun putting it back together so far. Every time I've gotten stuck I've posted a question on this site and have had help by the next morning. My boss bet me 15$ I couldn't get mine back on the road by 9/15 and I plan to take his money. I hope you take on your project and good luck to you.

[Aurel]

Eric,

I did it this winter without any prior experience in rebuilding engines, just being mechanically enclined and taking it step by step. I am quite happy with the result, you can hear it and read my lenghty thread about it.

For more CIS power, the true and proved way to go is 964 cams, 9.5:1 JE pistons and SSI heat exchangers. But if you plan on keeping your cylinders, they have to be Mahle to use JE pistons.
Most people will recommend to use Mahle cylinders for a rebuild anyways.
That is pretty much the best you can do with CIS.

In my case, I did rering my original pistons with alusil cylinders. So far so good, and I used DC15 cams because they work best with the 8.5:1 CR I have.

I say go for it IF you have the space and time to do it. Consider it a hobby that will keep you busy for several months. If you enjoyed building model cars or planes when you were a kid, you will reconnect with these old memories.

Aurel

[viejopatron]

It's just a machine. There's some tribal knowledge and a learning curve, sure. That's where this group can really help.

Do it, learn and have fun.

[ericheavner]

Thanks for the encouragement! I'm currently rebuilding a horizontally opposed lawnmower engine so if I can get it back together without any leftover parts, I'm gonna tackle the car. I'm sure that I'll be posting away on the board this fall.

[azasadny]

Eric,
You can do it! I went through "mechanic's hell" a few summer's ago and was ready to sell the car (search "Helga" here and you'll see what I went through). After all is said and done, I'm very glad I did much of the work myself and I'm very glad I have an excellent Porsche mechanic (Tab Tanner from Autobahn Garage in Findlay, OH) available when I'm over my head!

[hcoles]

yes it is a bit terrifying... follow the Wayne book and go slow, take good pictures and keep nuts/bolts/etc. in many small labeled plasitc heavy duty sandwitch bags... I had a stack of 3/5 cards and would put the items in the bag and write on the card and put that in the bag as well. I also got a good number of copier paper boxes and kept things separated. Also get a good set of lights so you can see what you are doing. Hopefully there are Pelicans near you that can loan tools and help out.

[wilke3169]

Eric, I rebuilt my engine 3 years and 25,000 miles ago. Very gratifying and educational. The engine cranks like a brand new one everytime.
My engine stand and tools then were used by capt.carrera to rebuild his Carrera 3.2. While I didnt help with the rebuild, due to a couple of hours between us, I think our discussions created an, "it can be done" attitude for Robert. Currently these same tools are being used by MCA in his rebuild. I have been a part of that rebuild helping with the parts where having another set of hands and eyes is a big plus.
All three of these rebuilds were done by first timers.
Charlotte isn't too far away for the tools to travel again.

[ericheavner]

Hey Kevin,

I have a great friend in Charleston who runs an I.T. company called PalmettoSoft. I regularly visit so when I get to that point (later this year, early next), I'd be interested in 'moving' the tools again. Thanks!

Eric
Triple Black '82sc

[3.2 CAB]

See, this is what is really great about the Pelican Community. Most members are very willing to share, knowledge, tools, etc. just to be able to help another member out. It is truly a great thing to see. Good luck to all!! Tony.

[deathpunk dan]

What level of ability is realistically required for a (mostly - obviously farming out the machine work) DIY rebuild?

When the time comes, I would like to rebuild my 2.2T engine with E pistons, solex or E cams and do all recommended other while-you-are-in-there type upgrades/updates.

I like to think I'm reasonably hands on, but the only engines I've ever really worked on have been BMW 6s and VW (sohc 4cyl and VR6), oh and many 2 stroke dirtbikes as a kid.

[304065]

You will need some special tools. . . .

[88911coupe]

Personally, one of the hardest things I've had to deal with is the fact that, even amongst true experts, there is a lot of disagreement over procedures and products. At some point you have to trust your instincts and make a decision, which can be a bit nerve wracking. And I'm talking about people who really know what they're doing...not the anecdotal "I used pig snot and it worked for me" type suggestions.

[mca]

Originally Posted by wilke3169

Eric, I rebuilt my engine 3 years and 25,000 miles ago. Very gratifying and educational. The engine cranks like a brand new one everytime.
My engine stand and tools then were used by capt.carrera to rebuild his Carrera 3.2. While I didnt help with the rebuild, due to a couple of hours between us, I think our discussions created an, "it can be done" attitude for Robert. Currently these same tools are being used by MCA in his rebuild. I have been a part of that rebuild helping with the parts where having another set of hands and eyes is a big plus.
All three of these rebuilds were done by first timers.
Charlotte isn't too far away for the tools to travel again.

I can honestly say that I never considered doing the rebuild myself until Kevin started egging me on (ever so slightly). I certainly would not have done it if he had not offered to help and answer my nagging questions.

There were certain steps where Kevin's help was invaluable - installing the pistons, setting the cam timing, and dropping / installing the engine to name a few. It really helps to have someone with experience lend you a hand. I am sure that there are plenty of resources in the Charlotte area.

Anyhow, don't be apprehensive. You can do it if you are methodical and patient ... you will spend the majority of your time cleaning and waiting on your parts to get back from the machine shop.

If you ever need any pics, I have tons from a 80 and 82. Although there may be slight differences, it could be of great help if you find yourself in a bind.

Best luck!

ps. I can't offer answers to some of your questions b/c I have yet to crank mine for the first time. Hopefully that will happen this weekend!

[JohnJL]

If you can paint-by-numbers you can do it. There must be a few hundred documented builds here and people always ready to help (or at least debate.)

Give it a whirl.