Richard's 3.2L total rebuild

[RichHawk]

I'm close enough to having a sealed up long block to taste it.

Here's the rub, I am cleaning ans prepping the parts as I go. So just about the time I think things should hit critical mass and just start falling in place, I have to stop and clean something else, and then paint it, or clear coat it, then finally bolt it on. In retrospect, I should have cleaned everything, including hardware before starting.

For instance, I Just painted the Valve covers. I chose red.




Still to go is cleaning the intake parts, blasting the fan, painting the fan (red), painting the Fiberglass shroud (red), Cleaning the exhaust, bolting all of that back on.

Also a word of warning to any other novices trying to glean knowledge here. Pay VERY strict attention to the order of operations in Wayne's book. I got comfortable with understanding what needed to be done, and failed to do a step by step following of directions.
My (most recent) mistake, I assembled and adjusted all of the rockers before installing the Carrera tensioners. Then when I removed my mechanical tensioning system from the right bank, the cam jumped a tooth because of all the spring pressures on the cam. So I had to re-Time the cam AGAIN. The cams had been easy to control with finger tension on the chain with only one rocker. Sure enough Wayne had Tensioners going in before the other 10 rockers.

Once the engine is together, I then need to replace CV boots, remove and clean the oil lines, oil tank, oil cooler. The list goes on and on...
Someday I might actually get to drive this thing..
Richard

[RichHawk]

Credit here for the idea:
Limiting Travel of the Pressure Fed Tensioners

And credit I beleive Jerry Woods came up with this Idea.

But having read enough to know that the Carrera oil filled tensioners can fail, I decided I would add a spacer to mine.

But before I went hunting at the local hardware store to find a spacer to buy and cut down, I thought I would check to see what I had around that could be modified to work.

Low and behold, the right inner and outer diameter was found. The oil pressure relief pistons that were replaced with new found a new job. I cut one piston using a dremmel tool into two spacers, and ground each spacer to 4.5mm length.
I was able to get the C-Clip retaining ring in the groove unlike what the above website says.

Viola! Upgraded tensioners, Zero cost.

Dimensions below are with new chains, good condition sprockets, only (.005") removed from the Cylinders, and no case machining. The length gives about 1/8" space between the fully collapsed plunger and the tensioned pivot arm.

Inner Diameter 1/2 inch (13mm for the Oil Pressure piston)
Outer Diameter 5/8 inch (15mm for the Oil Pressure piston)
length .177 inches (4.5mm)

Richard

[gearheadgreg]

Awesome progress. I am envious!

[byfdinky]

Can I hire you for my rebuild?

[RichHawk]

Originally Posted by byfdinky

Can I hire you for my rebuild?

Thanks for the vote of confidence, but No. That would only end in tears and anger. I've been near both but this has been my own project, and my own money, so I've no one to blame but myself.

Besides, did you ever see the Seinfeld episode where the cabinet maker drove Jerry crazy with all the nitpicking detail questions until Jerry just told him to build it how he wanted. Which of course was not at all what Jerry was after. Yeah I imagine it would be something like that.

If you want to hire someone, seek out Henry Schmidt. Supertec performance. He's a very experienced Porsche engine builder. I'm a hack by comparison.

Richard

[RichHawk]

There are advantages to having your Engine at your office. One of which is bolting on valve covers while on conference calls.

[RichHawk]

What a shame that this shroud will be mostly covered by other things.

[RichHawk]

Small progress this week. Alternator, fan, shroud and wiring harness.

[RichHawk]

So if you get a moment to comment, here's my simple question:
What is the next best power improvement / Flow improvement for the $ ?

What I got.
3.2L with brand new JE pistons measured at 9.9 CR
JD cams DC-20 (more aggressive than 964 grind)
Brand new everything heads, but stock springrates, and single plug
ARP rod bolts.
Stock intake system / injectors
Stock Heat exchangers
Hollowed out Cat
Steve Kasper Custom single in monster dual out muffler
Yet to be ordered: Steve Wong custom chip to match to the parts I got.

Guessing, I's say the stock Heat exchangers are the limiting factor of flow first. Changing them to SSI or headers changes the entire exhaust, which I am ok with, but that will be much later money.

Thoughts? Limitations?

These are the parts as I got them with the engine. I just couldn't resist putting the cams in, even thought I don't have the exhaust to take fullest potential of it.

And the Stock valve springs Do they limit my RPMS? IF so all I can hope for is Midrange improvements.

Thanks,
Richard

[88-diamondblue]

Great looking rebuild brings back a lot of good memories doing mine. I used the DC-22 in mine and really like them. I would talk with Steve Wong and John at DR Camshafts about the rev limit but if it were mine with stock springs I would limit to 6800. I had mine set to 7200 with performance springs from John. I rarely see anything above 7000 as not much left at that point. I went with 3.4 P&C's. With stock exhaust and a euro pre-muffler I can see the effects of not having enough exhaust capacity as the AFR's are getting rich starting at about 5800 rpm. I am looking at going with the 993 heat exchanger route when I can.

[gearheadgreg]

I need an excuse to break out the flow bench - send me an extra head and your complete intake and exhaust and I'll get back to you next month. Heh.

Seriously, i did flow the entire intake system of a CIS injected water-cooled VW and removed it piece by piece to see what the restrictions were. Very informative.

[RichHawk]

And it's damn near ready!!!

[RichHawk]

NOOO!!!! It's too wide!!!!!!!

Hmmm...
I guess this is a good reason to install a wider door. Where did I put that Sawzall??

[RichHawk]

Just kidding! I Measured things at least four times before putting the intake on to make sure it would clear this door. One inch on either side and it's a 34 inch wide opening

[RichHawk]

[Don Settergren]

Nice work. Have you thought about leaving the deck lid open when you drive to show that baby off? I won't hold you to it, but when is install planned?

[RichHawk]

Install was planned for Tomorrow. But the oil lines have been kicking my butt. And the weekend is full, so next week evenings?

There's still so much to do...

[RichHawk]

And we are ready to go in!

[gearheadgreg]

Great job Rich! Christian is likely in Kansas or close to it with his 3.2 now.

Whats that Cat doing on there?!?!? =)

[RichHawk]

Cat? That kinda looks like a cat, but it doesn't meow like a cat. Or for that matter do any other cat type things. You could say it's a bit hollow