Carrera Engine Reassembly Pics 3.2L Euro

[Determined]

I wanted to share some of my pictures of my reassembly progress of my 3.2L Euro. It's my first ever rebuild and it's been a lot of fun and thanks to everyone for their support. I'll post more as I move forward, today I performed my desk height check and tomorrow I'll install all cylinders and heads.

Thanks!

Alex

[ChrisBennet]

Hmm, something is missing here. Can't quite put my finger on it...
-Chris

[Determined]

Very true, it's the pistons. I took these pictures before I performed the work today. By tomorrow, I"ll have the pistons and heads installed. Oh, did you notice my homemade cylinder holders. I made my own out of 1/2" copper tubing...investment of $2.28 and my pipe cutter.

Alex

[boxermania]

Very nice work Alex......you can eat off that engine. I will be doing the same in a couple of month's to my 2.7.

1) Can you share whose head studs are you using, I saw the 12 point nuts and the rounded ends......
2) Is the fan and housing powder coated or painted?
3) Was there need for case work? If so, who did the work on the case and reworked the heads?
4) Are you satisfied with the amchine work?

BTW, I like those cylinder holders.....I have a pipe cutter too....hehehe

Thanks a bunch

Al

[Determined]

Thanks Al,

I must have hand washed and pressured washed this engine at least 12 times before reassembling.

The head studs are ARP and it came with the 12-point nuts and washers. I also used ARP rod bolts and a stretch gage to properly tighten them down.

I taught myself how to powder coat with a cheap unit from Harbor Freight. To avoid a tolerance stack up between the two I powder coated the fan and Hight Temperature Ceramic painted the housing, both were cured to a chemical resistant rock hard finish.

I did not need any case work, I just added the ARP hardware. The heads were done by Ted Robinson in Sunnyvale, a hell of a nice guy and very knowledgeable, very satisfied! It's not shown here but I also had the head chambers & valves treated with ceramic coating to try to minimize detonation. The exterior of the heads were also treated with heat dissipating coating, it's yet to be proven.

Throughout this project I made many of my own custom tools.

Thanks!

Alex

[Determined]

Alright, I got up early and installed my pistons and cylinders with .25mm base gaskets. All went smooth and it was not that difficult installing the circlips onto the pistons once you figure out a good approach. Following Wayne's book was very helpful and accurate. Next will be the heads but I'm going to double check each piston/head for clearance first. The solder approach works good for me.

Attached are a few more pictures.

Regards,

Alex

[Determined]

Here's today's work done, I went back and disassembled my heads so I could apply a very light film of lube to my valves stems. I had originally installed them dry but it seems like several recommended a thin coat of oil during assembly. Everything went smooth following Wayne's book. The heads and cam towers were easy, the cams fit and turned easily also. I have attached a couple of pictures, more will come as I progress. Oh, one question...I already performed the deck height inspection by following the solder approach. Both pieces of solder which were parallel to the crankshaft had sufficient clearance. The piece on the high side of the piston dome averaged about 1.60 mm at the thinest spot. Is there any reason to believe that I will encounter any problems during my piston top to valve clearance check? The solder I used was 3.2 mm diameter to start.

Regards,

Alex

[im4duke]

Looks nice. Thanks for sharing.

Can you elaborate on the coating you used on the heads? What is it called, and how is it applied?
Thanks.

[Determined]

Sure, the coating is a heat dissipating formula and is sprayed on and oven cured for a few hours. I don't remember off hand the technical name but I believe it is CBC2. I also had my pistons Tri-coated: Ceramic on crown (top Dome area), Dry film lube on skirts, and heat and oil dissipating coating under side of each piston. My valves where from Cam grinder and they were performance springs, I had them treated with SDFL-1 to help reduce heat from friction. My intake and exhaust valves where treated with ceramic on the tops and stems treated with SDFL-1. Whether they work or not...it's debatable but since I'm running a Euro set-up with high compression I'm doing what I could to minimize detonation. I also will be using a Steve Wong chip and plan on retarding the timing. Thanks for your interest and comments.

Alex

[KobaltBlau]

did you calculate your static compression from CCing etc?

[Determined]

Hi Andy,

I did not calculate static compression. I'm in your old town, Denver, currently on business but I can't wait to get back and continue working on my engine.

Regards,
Alex

[efhughes3]

How did this turn out?

[MBEngineering]

HI Alex
looks like you could do with a flywheel oil seal fitting tool, from the photo's??

regards mike

[Determined]

Hi Guys,

It's been a while since I been online, I have more pictures and will post soon. I'm in the process of moving and will update shortly, the engine is complete!

Alex

[Zork]

We live in San Jose and recently purchased a 1987 Porsche and are looking for a good mechanic in our area....do you have any suggestions. Thanks for your help.

[Hoffmanmotors]

Originally Posted by Determined

Very true, it's the pistons. I took these pictures before I performed the work today. By tomorrow, I"ll have the pistons and heads installed. Oh, did you notice my homemade cylinder holders. I made my own out of 1/2" copper tubing...investment of $2.28 and my pipe cutter.

Alex

LOL I was just thinking the other day how i can make my own cylinder holders! Now i know...

[Determined]

I'm back, moved into the new house last year and the baby was born. Finished most of the wife's "to do lists" and now I'm ready to finish this project. Current status: My engine is fully assembled and my last activity was rebuilding my engine blower fan with a new motor from Grainger. Just yesterday I picked up my new 915 with an LSD! A few things to check over before attaching the transmission then were ready to go back in. Pictures will be posted soon.

[Determined]

Here's a few pics during reassembly.

Alex

[Determined]

I have my tranny attached and ready to reinstall if only I could figure out best way to lift the dam thing while balancing it.

Alex

[Flat6pac]

I have the host Carrera jack adaptor..totally excellent investment