One of those days

[Don Settergren]

My rebuild has 5,000 miles on it and it runs perfectly. I wish you the same success and hope you don't mind as I relive it all thru your thread. Great progress so far.

As for the budget, the money will be well spent on your hot-red 911. Thanks for the photos.

[Ian Fulton]

To all you guys that have commented thank you for the comments and support.
To Lindy I have to say your case is a work of art. What cleaning procedure did you use. I am still working on the other half although almost done.
To Bill I am going to re-use the Alusils. I cannot measure any noticeable wear in the cylinders or pistons. The rings however are 80-90% of their wear limit. So what to do. Normally I am not a gambler but I don't have loads of money. SO my decision is to re ring using new Goetz rings and keep the old worn ones. If it all works then I get lucky. If not I have the old ones although they will not go back in the same position although I have documented which piston they belong to. Incidentally the Local Porsche people will sell me genuine rings for Alusil pistons but they are bloody expensive.
And to Ed yes I do have Wayne's book, plus Bentley and I have learnt a lot from the many people who contribute to this Forum.

[TibetanT]

Hey Ian:

Yeah, I thought you had Wayne's book. I can tell by the beautiful job you are doing. And, you are right about all the wonderful people on this forum whom share their respective experience to help us all get good results. Just when I think I have learned enough, something comes along to remind me how inexperienced I am...such is life.

As far as my high number of hours clocked cleaning, I must admit that since I am in no hurry I am cleaning the parts as they came off the engine. In other words, as I disassembled the engine each piece was then cleaned.

But, I am certainly going to try your methods for cleaning the engine case.

I will post pictures, when I get my camera skills "fixed." LOL

[lindy 911]

Ian,

Mine were just easy to clean, I got lucky and there was no coked oil staining. One thing I found is that it's easy to obsess with parts cleaning. The goal is to make sure there is nothing that will come off a clean part like grit or dirt. Also, if the part has a mating surface that requires a gasket or sealant, it needs to be perfectly clean of anything other than the metal it's made from.

Details are important but if you have a stained case and you're hell bent on getting the stain off, it's only going to be a cosmetic gain and nothing more. The motor won't run any better because it looks like something out of an ER. I got way too detailed with my cleaning and wasted a lot of time.

Enjoy the build!

Lindy

[Ian Fulton]

A friend of mine that has an oxy/acetylene set is not available for another week. Why did I require him? To put some heat on the crankcase spigots to break the thread seal on the head studs. Being impatient as I am I though what the heck I will try the stillsons on the broken stud. Guess what it came out with little effort. So I continued on. All studs came out with the stillsons and NO heat. 4 required a little more effort than the others. Sometimes in this world we get lucky eh.
See photo of the old studs and the new 993 studs which have just arrived

[lindy 911]

If you chase the threads in the case be careful and don't use a tap. There are some useful threads about what to do and what not to do.

Lindy

[Ian Fulton]

All the spare parts are arriving in droves. Still waiting on the ARP rod bolts and head reconditioning before I can start reassembly. In the mean time there is always more cleaning to do. I have sent some of the engine tin to out be powder coated. Black of course.
Regarding engine case sealants I have read all the threads and have made the decision to follow Henry's recommendation. While there are a number of different ones he suggests the one thing he has is experience with many of these engines. That is good enough for me. So I am currently sourcing all these various sealants

[Ian Fulton]

Well I am finally happy with the cleaning of all parts except for the final squirt with brake cleaner, clean wipes and compressed air on actual assembly.
Had the apprentices at work last week make some rod holding tools as per Wayne's book.
I have trial assembled all the rod and main bearings and checked with plastigage. Everything checked out fine.
My recorded hours spent so far now total 82.5 hours.
Now I am ready to assemble all the rods to the crank using new ARP rod bolts.
The birth of a new engine begins!

[Daviboy]

Ian great news. I also had in excess of 80 hrs in cleaning and prep work for my rebuild. It is an exciting and informative process which you will enjoy I am sure. I had a few wobbles during mine but if you take it slow and follow Waynes book you should have no issues. The area I found the trickiest was cam timing but there are a bunch of great threads on that one. Enjoy cant wait the see the rebuild pictures....

[Ian Fulton]

In one of my early posts I stated the rings were near their wear limit. What do I do? I have read all about re ringing Alusils and am now going to attempt it.
With my cylinders I have tried using Mothers mag wheel cleaner and polish along with grey scotchbrite on the first cylinder. I used the scotchbrite by hand with several cross hatch strokes both ways across the cylinder wall to replicate what a hone would produce. Then washed the cylinder in hot soapy water, several times dried with Kim wipes and air. When no more residue came on the Kim wipes I was happy that all the old lube/particles had been removed from the cylinder wall. This convinced me to move onto the remaining 5 cylinders. I will use the Goetz rings, although the local Australian Porsche experts told me they could source rings for Alusils for the price of $642.00 (too dear for me). Only time will tell whether you can successfully rering by this method.

[Ian Fulton]

Got the reconditioned heads back last night. Boy they look like a work of art, cleaned with new guides etc.Now they just have to be assembled.

[Ian Fulton]

Assembled all the heads this weekend, well almost until I either lost a valve stem seal or I didn't receive the full set. All came up good. I valve still to go.
The other thing I noticed in checking my reuse parts is that one of the oil pressure relieve valve springs is about 4-5 mm too short. I don't know how critical this is, I believe that it just means that oil is dumped into the crankcase rather than go through the oil galleries at a lower pressure.
Next step is to fir all the rods to the crank using my new ARP rod bolts.

[cgarr]

The spring that goes in the bottom should be around 86mm Do you have one about that long?

[Ian Fulton]

Craig, I don't have a spring that long. I have to order 1 more valve stem seal that I seemed to have misplaced, so I will order a new spring at the same time.

[Ian Fulton]

With Easter coming up along with ANZAC day and Picnic day, plus my wife is working over this period, I now have an ambitious plan to assemble the complete engine and have it installed back in the car by the end of April 28th.
This all assumes that I havent misplaced any other parts or nothing else untoward shows up. This time should allow replaing the oil pressure relief spring plus another valve guide seal. I have all the case sealing components (using Henry's much publicised method) plus all the other spare parts that I require.
I know this is a tall order but you have to have a goal to work to.

[Ian Fulton]

I have now assembled all the rods to the crank complete with ARP rod bolts and stretched to spec. Installed the oil pump into the case with new intermediate bearings, installed all main bearings complete with Moly lube and closed up the case. All in all I was happy how the case closing worked at my first attempt. I did not appear to have too little or too much adhesive or squeeze out on the surfaces. I guess time will tell weather it leaks.

Total time now spent is up to 92 hours. Over easter i will install the pistons, cylinders, heads etc and it will start to look like a new engine.

[Ian Fulton]

During the week assembled the first 3 pistons,cylinders and heads to the block. On track at this stage to meet my goal barring any stuff ups.

[Don Settergren]

Looking good. Soon you'll be timing the cam which is a truly momentous point in the build. Keep after it.

[JohnJL]

Hey, that's Wakefield!

You:


Me:


Hope your day ended better than this:





Good luck on the rebuild. I found using PR Tech for machinework VERY expensive but Rich and guys are very precise. Do not use Wynn's, the heads they rebuilt for me had to be re-built.

Good luck!

[Ian Fulton]

I've made good progress over Easter and at 5:00 p.m. Sunday night the assembly now consists of all pistons, cylinders, and heads installed. The rocker arms, shafts complete with seals ( bit of a fiddly job) cams, sprockets and cam covers are all installed. I have just finished timing cylinder number 1 to 1.25mm see photo attached. Number 4 to do tomorrow and then complete the rest of the engine.
Total hours to date is 124.5