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1977 2.7 Engine rebuild!
SmileWavy
http://sphotos-a.xx.fbcdn.net/hphoto...41433257_n.jpg I have always Loved the looks, the great performance and handling of a 911. I searched for about 6 months to year until I found the deal/ car that caught my eye. I purchased a 2.7 911 Wide body with 73k miles in March of 2012 from a gentlemen in Maryland. Driving this car home to Virginia was a dream! I am very pleased with my purchase. I noticed before I purchased the car that it was leaking oil "common problem" The seller clearly expressed that. I figured I would drive the car until I ran out of the keg of oil that was given to me at the time of purchase. Then after would follow a engine rebuild! The car was mechanically strong at the time of tear down and ran flawless! Minus the oil drops that seemed to follow and the annoying smoke that would end up from the oil dripping on the exhaust headers :rolleyes: Before the rebuild process I decided to repaint the car and replace the the carpet! https://lh6.googleusercontent.com/-W...004_122410.jpg The rebuild took place at 76,500. Find a reliable, knowledgeable rebuild-er. After doing plenty of searching I found rennsport systems! Reading nothing but the best reviews I figured I could sleep good at night trusting them with my engine rebuild! Engine goals: A safe reliable 230 hp! Speaking with Steve at Rennsport Systems he gave me a list of safe practices and procedures to follow on getting my engine where I would like it to be. His knowledge on these cars is astounding!! I know I have my engine in great hands. I tore down the engine and had it shipped to him where everything will be sorted out machine work will be done and a complete rebuild will go underway. Continue to follow as I will list my engine modifications and progress along the way!SmileWavy http://forums.pelicanparts.com/uploa...1360050326.jpg https://lh3.googleusercontent.com/-X...105_224208.jpg http://sphotos-a.xx.fbcdn.net/hphoto...93590607_n.jpg |
Great project! Tail was a nice addition ~
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Nice car.
Any chance you are from the Toyota MR2 world? Your location and evident skills seem familiar. |
Cool project, I'll be watching this thread. I have a '77 2.7 and when/if I need to rebuild I'll probably use this to guide me.
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Good luck - I'm doing a similar job with mine and will look forward to your updates for comparing notes.
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No I have owned a few Honda S2000s and a NSX I had some friends tear down the engine with the help of me, handing them tools and bagging screws and bolts for them! SmileWavy |
Very nice, look forward to seeing more.http://forums.pelicanparts.com/support/smileys/wat6.gif
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Nice looking car. I'm planning on the same front bumper. My body work & paint is going to have to wait though. I'm just starting to put my 3.2 back together.
I'm going to refresh the suspension, drive it for the summer, then get the body done over next winter. Do you have any shots of the rear of the car? cheers |
Thank you for all the positive feed back. I'm In the process of removing the front oil cooler now and all the hard and soft lines to clean them for the long-ability of the rebuilt engine! I have more pictures on my fb here Facebook If these pictures don't work let me know and I'll Find away to get them up SmileWavy
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Did you install the side mirror or were they already there? I've been looking to replace my stock mirror to a rs look. Let me know
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I replaced the mirrors! Changing the mirrors is as easy as changing the wiper blades, all you need is some time and a hex key
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Hi I'm looking forward to your rebuild. I also have a 77 2.7 Mine has a top end build only with new rs pistons and cylinders E cams and PMO carbs it is fantastic. Plenty of power and very smooth with no flat spots. 235 hp is possible how are you going to achieve it? I have been a customer of Steve's for a few years he's great.
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Since I have been waiting on the engine I have ordered some goodies!
New oil lines back to front, New center mount oil cooler and a new thermostat http://sphotos-g.ak.fbcdn.net/hphoto...46122539_n.jpg Replaced the headliner http://sphotos-c.ak.fbcdn.net/hphoto...51055656_n.jpg http://sphotos-a.xx.fbcdn.net/hphoto...99952011_n.jpg http://sphotos-h.ak.fbcdn.net/hphoto...22028203_n.jpg New rear window seal on the way, As it got a little chewed up when I pulled the rope around the seal :eek: Sure thats going to leak! Replaced the carpet http://sphotos-g.ak.fbcdn.net/hphoto...57542416_n.jpg http://sphotos-h.ak.fbcdn.net/hphoto...93537424_n.jpg http://sphotos-g.ak.fbcdn.net/hphoto...32822772_n.jpg http://sphotos-a.ak.fbcdn.net/hphoto...07550059_n.jpg Replaced the front carpet http://sphotos-g.ak.fbcdn.net/hphoto...52220340_n.jpg More coming soon!!! Thanks to elephant racing for the oil lines from the tank forward and back! Pelican for the headliner, trunk carpet and interior carpet!!! |
More Pictures and up dates
Finishing up the oil lines! Thank you Elephant racing, This was a easy to install and very well assembled cooling kit!! https://lh3.googleusercontent.com/-l...509_183300.jpg https://lh5.googleusercontent.com/-I...509_164114.jpg Test fitting the front mount cooler https://lh5.googleusercontent.com/-3...503_135549.jpg |
Changed the gauge lights to leds Purchased from Etarga here on pelican. These were very easy to install and really made the interior lights come back to life!
Carefully pry out the gauge https://lh6.googleusercontent.com/-x...924_135637.jpg The instructions will show you where to pry out the old bulbs and how to replace them https://lh3.googleusercontent.com/-h...924_135657.jpg Time to let them glow! Before is on the top https://lh4.googleusercontent.com/-b...924_153254.jpg |
Ordered some parts soon to install
Msd 16al, Msd High Vibration coil and Magnecor wires! https://lh3.googleusercontent.com/-D...921_012703.jpg Thanks Rennline.com - Porsche Performance Parts, Accessories & Race Parts for Porsche, BMW & Audi for the battery relocation kit! https://lh3.googleusercontent.com/-U...910_152851.jpg This kit involves exteding the batery cable to the smuglers box along with installing a new ground point on the stearing coloum! Waiting to install these soon before the delivery of the engine :D https://lh3.googleusercontent.com/-d...101_152938.jpg Red wire is the power wire to the amp under the passenger seat powering two 8 inch subs for a little extra sound! (the cables are just laid about for the moment) |
I was also informed to replace the gas tank or to have the old one cleaned and resealed along with replacing the fuel lines front to rear, Thus preventing clogging up the Carbs!
New fuel tank from Porsche https://lh4.googleusercontent.com/-c...025_155600.jpg Draining the fuel tank from the drain plug located at the bottom of the tank using the head of a 3/4th spark plug socket and an extension, No special tools here... YET! https://lh5.googleusercontent.com/-P...028_164945.jpg Closely examining the fuel lines from the fuel pump to the rear I noticed the lines were damaged! Fire hazard saved! Thanks Steve SmileWavy. Examining and replacing of the fuel lines is something I strongly suggest! This job was pretty easy after removing the transmission for better access to the fuel lines at the end of the tower! This is viewing the pressure and the return line at the fuel pump between the two front wheels, looking closely you will notice ones damaged https://lh3.googleusercontent.com/-9...029_130533.jpg Removing the fuel pump is easy, Remove the two wires under the rubber boots, each wire has a different sized pole and different sized Mm nut, these two can not be hooked up wrong. Disconnect the fuel lines also unscrew the clamp holding the fuel pump, slide the pump out of the way. Place the pump in a baggie to prevent grit from getting in the system. https://lh5.googleusercontent.com/-i...029_142534.jpg https://lh4.googleusercontent.com/-t...029_150159.jpg Disconnect the fuel vdo sending unit and also all other hoses connecting the tank to the filler, unscrew the 3 hex head screws clamping the tank to the body. The tank should then be free to remove from the top! https://lh3.googleusercontent.com/-N...029_131816.jpg After the tank is removed now is a good time to replace and repair any sheet metal damage in the front of the tub. https://lh6.googleusercontent.com/-A...029_135837.jpg |
Cleaned Oil tank prevents old crud from getting into the oil system that can wipe out bearings and cams. Thanks pacific Oil Cooler Services Pacific Oil Cooler Service, Inc. - Home Thank you
Returned after cleaning, Be sure to order a new gasket for sealing the oil level unit to the tank and all other hardware. https://lh6.googleusercontent.com/-8...925_125552.jpg |
https://lh6.googleusercontent.com/-t...113_145648.jpg
New parts soon to be installed New fuel lines w/grommets Bosch fuel pump Clutch cable Rennline block off plates Pedal Bushings Sunroof seals Inner + outer shift coupler boots Rennline blower motor cover Rennline block off plate Dual deck lid shocks |
Rennline block of plates and blower motor cover installed!
https://lh6.googleusercontent.com/-j...120_145534.jpg |
subscribed!
very nice documentation of your progress, please keep us updated. i like the two tone (tan/black) of your interior & the exterior color as well! |
Hello,
Cool picture in the site,otherwise every information are good.I will agree to other member,i personally talk about the site with my friend.thanks Sacramento Airport Shuttle |
Replaced the Clutch cable. Removed it from where it connects to the front of the tunnel, then pulled it out through the rear. Fed the new one in and reconnected it at the front.
https://lh4.googleusercontent.com/-D...203_145540.jpg Cleaned out the fuel filler and replaced the fuel filler flap https://lh6.googleusercontent.com/-u...205_144231.jpg Replaced the rear deck lid strut with pelicans dual heavy duty strut! These two shocks are easy to install and hold the lid up with no struggle https://lh6.googleusercontent.com/-k...205_143942.jpg New fuel pump and fuel lines with correct banjo fitting https://lh6.googleusercontent.com/-2...205_172046.jpg New fuel pump and fuel lines installed https://lh4.googleusercontent.com/-s...215_152458.jpg New fuel tank Installed from Porsche, reused the Vdo fuel level sending unit, Rust clean up will follow on front battery tray https://lh4.googleusercontent.com/-w...215_152533.jpg Painted the rear engine compartment https://lh4.googleusercontent.com/-f...219_165617.jpg |
You need 17 to 20 turns on the clutch cable into the clevix in order to be able to adjust the clutch without running out of threads in the rear.
Bruce |
2.7 rebuild specifics
Nice thread. Thanks for posting. curious about the 2.7 rebuild you are going to do. You could add 9.5 JEs,40 mm carbs, E cams, SSI 2 in I out muff. but would that give you the 230 hp you requested? Wouldn't that be 200 to 210? best
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Awesome thread. I just started the rebuild of my 77. Going to go with a 3L engine. Fuel tank is out getting cleaned, that was the first step after collecting the pieces and parts from the seller. Was debating about whether or not to go with the wide body look. Afte seeing yours... Done! It's going to happen!
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More updates Rennline Pedals installed https://lh4.googleusercontent.com/-9...222_154054.jpg Oil tank going back in after being cleaned up and repainted from paciffic oil coolers new gasket on the oil level sending unit and new boot for the wire! Ground wire added https://lh6.googleusercontent.com/-1...222_153706.jpg New tail lenses installed https://lh6.googleusercontent.com/-8...222_153608.jpg New engine+transmission mounts in Oil filter ready to go! https://lh6.googleusercontent.com/-k...231_141449.jpg |
Love the progress! Curious - where did you get the rockers from?
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They were installed by one of the previous owners! They look like they have been on the car for a long time and it looks like they were installed with coopper:confused: New sunvisors installed from Porsche! https://lh3.googleusercontent.com/-c...109_172153.jpg Still waiting on the engine!!!! |
Fuel lines are going in with the fuel filter and the crank case breather.
Big thanks to Len Cummings at Auto Sport Engineering for making some lines for me from the tunnel lines up! These were direct fit! https://lh4.googleusercontent.com/9q...KzeQaw=s615-no Modified oil catch can will be going in next! https://lh6.googleusercontent.com/-H...204_122050.jpg |
Installed the Crank case breather after shortening it 2 inches and putting a new hose fitting on it from 1.5 inch to 1 inch to accommodate a 1 inch hose from the oil tank to the breather, Then changing out the drain fitting from a straight to a 90 degree brass fitting for easier routing.
https://lh4.googleusercontent.com/-a...220_201151.jpg Glued in the door seal and screwed in the felt seal that runs on the top of the door jam https://lh5.googleusercontent.com/-L...220_193844.jpg https://lh4.googleusercontent.com/-s...220_194218.jpg Doors seals nice and snug now:D |
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Installed some Recaro sportster seats!
http://forums.pelicanparts.com/uploa...1400220100.jpg http://forums.pelicanparts.com/uploa...1400220224.jpg Have the Msd in place! http://forums.pelicanparts.com/uploa...1400220326.jpg Battery in the smugglers box! http://forums.pelicanparts.com/uploa...1400220366.jpg New key and key head! http://forums.pelicanparts.com/uploa...1400220408.jpg Cleaned up the transmission! http://forums.pelicanparts.com/uploa...1400220463.jpg Pictures of the engine! http://forums.pelicanparts.com/uploa...1400220627.jpg http://forums.pelicanparts.com/uploa...1400220676.jpg Dyno numbers! http://forums.pelicanparts.com/uploa...1400220746.jpg |
Wow, great numbers. That thing will haul butt...too bad it wasn't a local that did the build, I'd have to talk with them about mine, haha.
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Got the car running on 6/16/14 I've included a link of the car running and some pictures of it out of the storage unit SmileWavy
Link to car running and walk around video! 77 porsche 911 2.7 walk around - YouTube Engine about to go in https://scontent-a-iad.xx.fbcdn.net/...86518566_n.jpg Engine in! https://scontent-a-iad.xx.fbcdn.net/...ab&oe=546960F3 Gas station https://fbcdn-sphotos-d-a.akamaihd.n...616e0e24e6163f Top of Skyline Drive in Virginia https://fbcdn-sphotos-f-a.akamaihd.n...10880416_n.jpg Thank you for all the help and support! Couldn't have done it without the help of so many great people on this website. |
Walk-around video looks like a for-sale video...but I don't think that's the case, right>?
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It's on eBay
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Very nice car! If I was in the market I'd be all over it. Good luck with sale!
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