ARER Part 1
 

Hi guys thanks for taking the time to read this.... assuming you are. Anyway just to explain the title, I did not want to just call it Another Engine Rebuild as that has been flogged to death so after my wife caught me snapping on the surgical gloves in the garage and saying and I quote " This is going to be really anal isn't it?" I decided to call the thread the Anally Retentive Engine Rebuild (ARER) so here is part one.
Spent about three hours last Friday morning re-cleaning the case halves in readiness for the build.
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Next up cleaning down the crank and rods with carb cleaner and alchohol wipes. Lubed up the new rod bearing and installed onto the crank, torqueing the rod bolts to 20Nm plus 90 deg.
After that re-assembled the intermediate shaft and oil pump ready for installation.
Dropped the crank into the case after a bit of a fight with #8 bearing dowel pin, but went in ok in the end.
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Installed the oil pump seals cleaned the new timing chains and placed in the gears then dropped whole assembly into the case.
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Checked backlash between crank and intermediate shaft the non technical way just by rocking the gears, very slight movement seems good.
That was about it for Friday all in all about 6 hours work and very satisfying I must say.

ARER Part 2
 

So bright and early Saturday back out to the garage to set about sealing up the case halves, this was the nerve racking part I must say. So I uncovered the case on the stand and re-cleaned the seal areas in preparation for applying the Threebond. So after a deep breath got the brush out and applied Threebond to necessary areas prepared all the through bolts with o-rings and took the right case half and dropped it onto the left. Good thing was the halves came within about a 1/4" of each other and stopped so I took the time to pre-install the through bolts placing the o-rings, washers and acron nuts on ready to tap the halves together.
So tapped the halves together and then quickly went about torqueing down the through bolts.
Oh forgot to mention I spent a fraught hour before this searching for the 12th through bolt, which of course does not exist. Was not until I was standing looking at the case that the penny dropped that there should only be 11....
Anyway the cases were now together and no time for looking back now. Got all the outside case nuts on and torqued down, all in about 15 minutes.
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Wow cant believe I am this far along.
Ok after a breather got the oil breather cover, thermostat, and switch back in and torqued down. Installed the oil relief pistons with all new springs and pistons on. Installed all new chain ramps to left and right side.
Next up was installing the flywheel which went smoothly, then to the back and on went the pulley.
So that was it for Saturday short block completed.
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So going to be a few days before I get anything else done and my P&C's are stuck in customs as I need an import permit for them so by Thursday I should be ready for Part 3 stay tuned if I am not boring you too much

Thx

Looks like your doing a great job Dave. Keep us posted and thanks for the pictures.

It looks like you are reusing the lower "Delivar" studs. If so you are making a huge mistake.

You should know, good eye Henry.

Henry they are coming out today....

Offside
 

Was Peter Lorre or a bat ever the inspiration for the 911 motor?
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Permit Approved
 

Well I got my import permit this morning for the P&C's so one the clearing agent has completed the paperwork should be able to collect on Monday. Thats ok as it has given me the time to hand polish the heads to some degree...