Lapkritis - I appreciate your perspective, but hey, I asked for input and I'm getting it. If I didn't want some input and other perspectives, I wouldn't post on the internet. I'm a big boy, I'll make up my own mind.

I've owned 6 Corvairs, all with less than 100 RWHP. I quit measuring my dick a long time ago and just learned to enjoy the ride. :)

Henry - You're making some compelling points. I just couldn't picture a way to split the case without turning this into a full "New P&C, rebuild heads, new bearings, full engine porn" project like yours and others posted here. And I can't justify that on this car, when the engine ran so well.

You're right, however, I know nothing about the history beyond a 1500 mile drive home with it. No rod knock on the trip, but it could have been overrevved a dozen times in the past for all I know. My wife made a good point last night when I said that there was no indication of rod problems and she pointed out that there were no indications of broken head studs either until I pulled the valve covers.

If I can really address the rod bolts for <$1000 that changes the risk vs. reward equation compared to $5000+.

Honest rookie question - if I buy recon rods, do I need new wrist pins and bushings as well? Or can I re-use any of that?

Side note: Apparently there is a nationwide shortage of steel head studs at the moment. Pelican has only 9 steel studs, Supertec doesn't have any of theirs, and the Pelican guys had to dig deep from another supplier to find these for me.

Look what showed up today!
http://i1269.photobucket.com/albums/...ps23b9bc34.jpg

Risk vs. Reward example: I didn't mind spending a bit over $400 to replace fuel lines even though mine weren't leaking. Unknown age and a common failure point that I can address for $400 and not burn the car down? Sold. Whiz, Len is at lenDOTcummingsATverizonDOTnet

Mr. Project,

FYI if you pull the cylinders I believe you could pull the rods without splitting the case. Maybe not ideal but then rod recon and new bolts are well within reach. I did this to check deck height on all 6 cylinders during build up.

Mr P have you made any progress? Would be interested to know current $$$ and labour hours to date.

Many thanks
Ed

I did decide to bite the bullet and split the case. Just got the case split yesterday and have the parts heading to the machine shop tomorrow. Here's what I'm expecting cost-wise for the case split portion of this 'build':

ARP 204-6005 rod bolts - $230 on ebay
Machine shop recon rods - $110 for set
Machine shop clean/inspect crank and clean case - $100
4 additional chain ramps - $31
IMS bearings - $32
Connecting rod small end bushings - $33
Case gasket set - $54
Rod bearings (haven't ordered these yet) - $150
Main bearings (not sure if I can reuse or not) - $200
Oil pump lock tabs - $13
Flywheel bolts (2) - $5
Loctite 271 - $7.75
Loctite 574 - $25
Curil-T - $14
Cleanroom wipes - $9


I picked up another Subaru project yesterday as well, so those are the 2 additional heads in the shot. Hoping that the profit from that project will cover some of the scope creep on the 911. :)

http://i1269.photobucket.com/albums/...ps69e5f873.jpg

Couple references here to re-using main bearings. Do these look reuseable? Or should I replace (assuming that crank is OK for std/std.)?

http://i1269.photobucket.com/albums/...ps2ffd0b0a.jpg

Along those same lines, how would I know if the nose bearing needs to be replaced (assume crank is OK)? I see what looks to be some oil staining but no major signs of wear on the inner surfaces.

http://i1269.photobucket.com/albums/...ps1f160539.jpg
http://i1269.photobucket.com/albums/...ps61d34987.jpg
http://i1269.photobucket.com/albums/...psfeb9bfc4.jpg
http://i1269.photobucket.com/albums/...ps59ab3a62.jpg

Nice picture, thanks !

This should be replaced, imo.


can't say about the no:8, bu usually they are reusable.

You can tell when I go clean up and borrow the DSLR from my wife rather than using my phone while wearing my greasy nitrile gloves, can't you. :)

Finally some progress, but a stumbling block tonight.

Crank checks out to STD, I double-checked and measured it at 54.991mm
Rods reconned by the machine shop and I measured them at 58mm
Rod bearings are supposedly STD and I measured them at 1.5mm

I plastigauged the rod bearings after torquing down the ARP bolts and got a good result - about .030.

However, there appears to be a 'pinch' where the side of the rod bearing is getting hung up and crushed. After torquing the rod bolts down, the rod would NOT rotate. After removing it, the brand-new bearing has some odd kind of wear mark.

Help? I'm rather stumped.

http://forums.pelicanparts.com/uploa...1375583348.jpg
http://forums.pelicanparts.com/uploa...1375583358.jpg
http://forums.pelicanparts.com/uploa...1375583369.jpg

Caps on backwards will bind up.

FWIW I went through the "should I or shouldn't I" exercise on my 3.2 rebuild. I ended up splitting the case and doing the full job. Now, with the car back on the road it is running perfectly and I am enjoying the greater security of knowing nothing was left to chance (to the best of my ablity that is). At the time, the negative was the extra money. I ended up doing everything I hoped to save money on (e.g. new P's & C's). But six months later I don't miss the money anymore.

A lot of people do seem to have no issues leaving the bottom end alone, but I ended up following Henry's line of thought on the entire build and it works for me.

Wow, such an obvious and simple error - I was so focused on getting the stretch gauge in position I bet that's exactly what I did. Thanks, I'll hopefully try again tonight.

How is the project going?

I got side-tracked on another budget rebuild of a 2.5l DOHC Subaru motor. Got that done and back in the car last weekend, and got the chamfer tool and wrightwood gasket set in the mail this week, so I'll hopefully be back to the Porsche soon.

http://i1269.photobucket.com/albums/...psfe831ffe.jpg

I have been following this thread since there is valuable information from Henry's experience.

Now, I am wondering about these rod bearings which seem to have "wiped" against the crankshaft.

Can these new rod bearings, or rather should these, be used or would a another set be wise? (Of course, the plastigue came in within spec and the engine was never run, but I am always paranoid about stuff such as this.)

GL with your build! I was happy to hear/see you split the case.:)

Good question on the bearings, I'm curious as well. I measured them in every way I could, and couldn't detect any difference. I did go ahead and reuse them, although I mixed them in with other bearings rather than using both on the same rod.

I re-plastigauged every rod bearing and put all of the rods on the crank today, all went well and seems like a good amount movement on all rods.

I did more case cleaning and was hopefully going to start case assembly, but ran into a stopping point with the piston oil squirters (#3). One of them is being very stubborn, and despite a full 120+psi and some soaking with various thinners and solvents today, it refuses to open up. The other 5 are fine, and I've been through all of the threads I could find on the subject. Soaking it in Kroil overnight now and will try again tomorrow.

http://i1269.photobucket.com/albums/...psa560a612.jpg

In between other projects over the last several weeks I did manage to get all of my sheetmetal and other parts sandblasted and painted. I used a hi-temp engine paint from Summit Racing rather than powdercoating. I wanted to try something different, something repairable, and my guy that I usually do powdercoating with hasn't been returning my calls. :(

http://i1269.photobucket.com/albums/...ps40302da0.jpg

Yeah, overnight in Kroil and 4 hours in "MEK Alternative", with a good tight seal and 130psi - nothing. So it looks like I'm stuck for another couple of weeks while I wait for an oil squirter from our host.

Finally, some progress! The piston oil squirter was a bugger to remove, but eventually the slide hammer won out. After getting it replaced, the rest of the case assembly went quickly and smoothly last night.
http://i1269.photobucket.com/albums/...psfa6cdcce.jpg

http://i1269.photobucket.com/albums/...ps934f45c0.jpg

I did end up buying the Wrightwood gasket kit after getting a little nervous about some posts RE: the VR kit. Thus, I have over-spent a bit on some duplicates that I'll try to return or sell off.

More progress from last night: I'm on my way to a flat 3!
http://i1269.photobucket.com/albums/...ps7d96dc32.jpg

The pistons and cylinders are not very clean, because I didn't want to pull the pistons out of the bores and therefore didn't want to get cleaning solution trapped somewhere it shouldn't be. I'll make sure the sealing surfaces are clean and then hit the fins with brake cleaner and such after the heads are on and things are sealed up a bit.

More progress - my neighbor has been telling me that there's no way I'll be driving the car again this year. I have more to do than just the engine - but I'm trying to prove him wrong. :) I get a couple of hours to work each night this week after the kids are in bed, so I'm hoping between evenings and this weekend to have the engine assembled and ready to re-install.

http://i1269.photobucket.com/albums/...ps2f035ef5.jpg

Be Careful!
 

From this point on during reassembly, be certain to keep all of the openings in the block covered or plugged. It is remarkably easy to drop a small nut or washer into the block. Usually they will bounce around until they find the best hiding place! Sometimes the offending piece can be fished out but sometimes it will require splitting the block again! While doing the assembly work on the camshaft timing gears I turned the engine slightly in the stand to the side I was working on was a bit lower than the rest of the block "just in case" a small nut, bolt washer or woodruff key got loose! Paranoid? Maybe, but better safe than sorry!

Good tip, thanks. I've been using a large plastic bag and various fresh rags to keep any area I'm not actively working on covered. Even while installing the head studs I had all of the cylinder holes in the case covered in case I dropped one of the nuts that I was using to drive the studs in.

I hesitate to say this and jinx myself, but it's gone smoothly so far. Mating the case halves, piston circlip installation, etc. I haven't had any issues or real difficulties up to this point. The cam towers will be a lot of work, and I did buy the RSR rocker shaft seals, so that will be more opportunities to screw something up.

Timing the cams is the last hurdle, then smooth sailing. Take lost of pics. If you have an issue it's reasuring to be able to look at the pics and know it was done right.

Lots of people told me my car would never go back together. Ye of little faith.

Enjoy the process

Chris

73 911 E

More progress. Had a lot of trouble getting repeatable measurements on the Cam sprocket alignment last night. Probably just going to stick with the 4 shims on each side that it had before.
http://forums.pelicanparts.com/uploa...1379672696.jpg

Can you tell us why you went with these instead of the $351 option from PP: Pelican Parts - Product Information: 930-110-595-05-M260

I'll be crossing this bridge soon...

Great work so far, look forward to seeing you button it up. It was entertaining for me to read this thread all the way thru, started out thinking "hey that sounds like my rebuild" then "oh boy he's going split case".

Looks great. I had a similar experience and when I did get a repeatable measurement with my straight edge that was within spec, the chain would catch on the sprocket every 4-5 engine revolutions. I think it's a bit of a black art especially with the case seam not being flat between the halves. I would recommend the same - turn the engine by hand about 50 times and observe the chain action and pre-lube it at the same time. Observe if the sprocket is hitting the side of the chain link and adjust accordingly.

In my wildest dreams I had hoped to have the engine back in the car this weekend. That's not going to happen, but there has been good progress!
http://forums.pelicanparts.com/uploa...1379889337.jpg

If memory serves, that's just the one line of the three piece set.
All three lines OEM were in the $700-800 range IIRC.

http://forums.pelicanparts.com/uploa...1380018194.jpg

Every night, I think I will have things wrapped up and slide the engine back in. Not yet! Shooting for Thursday night now...

Well, I got distracted again because I had to put up a shed in the backyard before winter hits, but I've been squeezing in late-night time on the 911 wherever I could. And finally, last night, success!

This is after the 20-minute run-in and initial oil change.

video link: VID_20131006_215634_328.mp4 - YouTube

<iframe width="420" height="315" src="//www.youtube.com/embed/t-BXzAZFybU" frameborder="0" allowfullscreen></iframe>

It's been so long that I don't really remember what it sounded like before, but it sounds OK to my ears at the moment, does it to yours?

The only real issue I had when trying to get it started up was that the CHT sensor connection came loose (I must not have had it fully clicked in). That caused flooding and very poor running initially, and since it sounded and felt like a big vacuum leak, I spent a fair amount of time looking for that, plus pulling plugs, doing some compression checking, triple-checking distributor installation, etc.

After the 20 minutes or so of run-in:

• No massive oil leaks
• No horrible noises
• Seems to be generating oil pressure
• No meaningful smoke out the tailpipe

I have a few things to tidy up in the engine compartment, and then I have a lot of work to do on the rest of the car (interior and HVAC are dismantled, suspension and brakes are only partially assembled), but this is a big step towards driving it again!

Sounds good to me - congratulations! Great feeling, isn't it?

I hope your neighbor was listening...

GK

OK, here's a breakdown of what I spent on this project and where the money went on this 'Budget' build. Hopefully this is helpful to others in a similar situation.

First up are the items related to splitting the case:

<!DOCTYPE html>

<html><head><meta http-equiv="Content-Type" content="text/html; charset=UTF-8"><title>Engine project</title><meta http-equiv="X-UA-Compatible" content="IE=8;IE=9;chrome=1;"><meta name="lsq" content="1"><meta name="trixrows" content="126"><meta name="trixr1" content="0"><meta name="trixr2" content="68"><meta name="trixdiv" content="20"><meta name="trixcnt" content="4"><meta name="trixlast" content="8"><link rel="stylesheet" href="./12_files/3971517159-tiler_view_ltr.css" type="text/css"><style>html {overflow:visible};</style></head><body style="border:0px;margin:0px"><style>.tblGenFixed td {padding:0 3px;overflow:hidden;white-space:normal;letter-spacing:0;word-spacing:0;background-color:#fff;z-index:1;border-top:0px none;border-left:0px none;border-bottom:1px solid #CCC;border-right:1px solid #CCC;} .dn {display:none} .tblGenFixed td.s0 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:bold;font-style:normal;color:#000000;text-decoration:none;text-align:left;vertical-align:bottom;direction:auto-ltr;white-space:normal;overflow:hidden;border-top:1px solid #CCC;border-right:;border-bottom:;border-left:1px solid #CCC;} .tblGenFixed td.s2 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:normal;font-style:normal;color:#000000;text-decoration:none;text-align:left;vertical-align:bottom;direction:auto-ltr;white-space:normal;overflow:hidden;border-right:;border-bottom:;border-left:1px solid #CCC;} .tblGenFixed td.s1 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:normal;font-style:normal;text-decoration:none;vertical-align:bottom;direction:Context;white-space:normal;overflow:hidden;border-top:1px solid #CCC;border-right:;border-bottom:;} .tblGenFixed td.s5 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:bold;font-style:normal;color:#000000;text-decoration:none;text-align:right;vertical-align:bottom;direction:Context;white-space:normal;overflow:hidden;border-right:;border-bottom:;} .tblGenFixed td.s6 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:bold;font-style:normal;color:#000000;text-decoration:none;text-align:left;vertical-align:bottom;direction:auto-ltr;white-space:normal;overflow:hidden;border-right:;border-bottom:;border-left:1px solid #CCC;} .tblGenFixed td.s3 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:normal;font-style:normal;color:#000000;text-decoration:none;text-align:right;vertical-align:bottom;direction:Context;white-space:normal;overflow:hidden;border-right:;border-bottom:;} .tblGenFixed td.s4 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:normal;font-style:normal;text-decoration:none;vertical-align:bottom;direction:Context;white-space:normal;overflow:hidden;border-right:;border-bottom:;border-left:1px solid #CCC;} </style><table dir="ltr" border="0" cellpadding="0" cellspacing="0" class="tblGenFixed" id="tblMain"><tbody><tr class="rShim"><td class="rShim" style="width:0;"></td><td class="rShim" style="width:334px;"></td><td class="rShim" style="width:120px;"></td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s0">Case split items</td><td class="s1"></td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Machine shop - Recondition rods (big end only, small ends were in good shape)</td><td class="s3">90</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Machine shop - measure and polish crankshaft</td><td class="s3">35</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">ARP rod bolts</td><td class="s3">225</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Wrightwood case gasket set</td><td class="s3">100</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Case sealant - Loctite 574</td><td class="s3">25</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Curil-T sealant</td><td class="s3">14</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Threadlocker - Loctite 571</td><td class="s3">8</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Machine shop - wash case</td><td class="s3">35</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Case-saver insert for bell housing stud</td><td class="s3">11</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Chamfer tool from McMaster-Carr</td><td class="s3">20</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Kimwipes clean room wipes</td><td class="s3">9</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Brake cleaner and other cleaning solvents</td><td class="s3">50</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">piston oil squirter</td><td class="s3">33</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Main bearings (std) 1-7</td><td class="s3">210</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Rod bearings (std)</td><td class="s3">152</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">IMS bearings (inner and outer)</td><td class="s3">32</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Assembly lube</td><td class="s3">5</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Chain ramps</td><td class="s3">37.5</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Piston retaining circlips</td><td class="s3">15</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td class="s4"></td><td></td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td class="s4"></td><td class="s5">1106.5</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td class="s4"></td><td></td></tr></tbody></table></body></html>

Next are the items that were specifically related to the head stud replacement, and then some of my "Scope Creep" items:

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<html><head><meta http-equiv="Content-Type" content="text/html; charset=UTF-8"><title>Engine project</title><meta http-equiv="X-UA-Compatible" content="IE=8;IE=9;chrome=1;"><meta name="lsq" content="1"><meta name="trixrows" content="126"><meta name="trixr1" content="0"><meta name="trixr2" content="68"><meta name="trixdiv" content="20"><meta name="trixcnt" content="4"><meta name="trixlast" content="8"><link rel="stylesheet" href="./12_files/3971517159-tiler_view_ltr.css" type="text/css"><style>html {overflow:visible};</style></head><body style="border:0px;margin:0px"><style>.tblGenFixed td {padding:0 3px;overflow:hidden;white-space:normal;letter-spacing:0;word-spacing:0;background-color:#fff;z-index:1;border-top:0px none;border-left:0px none;border-bottom:1px solid #CCC;border-right:1px solid #CCC;} .dn {display:none} .tblGenFixed td.s0 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:bold;font-style:normal;color:#000000;text-decoration:none;text-align:left;vertical-align:bottom;direction:auto-ltr;white-space:normal;overflow:hidden;border-top:1px solid #CCC;border-right:;border-bottom:;border-left:1px solid #CCC;} .tblGenFixed td.s2 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:normal;font-style:normal;color:#000000;text-decoration:none;text-align:left;vertical-align:bottom;direction:auto-ltr;white-space:normal;overflow:hidden;border-right:;border-bottom:;border-left:1px solid #CCC;} .tblGenFixed td.s1 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:normal;font-style:normal;text-decoration:none;vertical-align:bottom;direction:Context;white-space:normal;overflow:hidden;border-top:1px solid #CCC;border-right:;border-bottom:;} .tblGenFixed td.s5 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:bold;font-style:normal;color:#000000;text-decoration:none;text-align:right;vertical-align:bottom;direction:Context;white-space:normal;overflow:hidden;border-right:;border-bottom:;} .tblGenFixed td.s6 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:bold;font-style:normal;color:#000000;text-decoration:none;text-align:left;vertical-align:bottom;direction:auto-ltr;white-space:normal;overflow:hidden;border-right:;border-bottom:;border-left:1px solid #CCC;} .tblGenFixed td.s3 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:normal;font-style:normal;color:#000000;text-decoration:none;text-align:right;vertical-align:bottom;direction:Context;white-space:normal;overflow:hidden;border-right:;border-bottom:;} .tblGenFixed td.s4 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:normal;font-style:normal;text-decoration:none;vertical-align:bottom;direction:Context;white-space:normal;overflow:hidden;border-right:;border-bottom:;border-left:1px solid #CCC;} </style><table dir="ltr" border="0" cellpadding="0" cellspacing="0" class="tblGenFixed" id="tblMain"><tbody><tr class="rShim"><td class="rShim" style="width:0;"></td><td class="rShim" style="width:334px;"></td><td class="rShim" style="width:120px;"></td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s0">Head stud items</td><td></td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Machine shop - drill and helicoil exhaust studs on 5 heads</td><td class="s3">130</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Machine shop - EDM exhaust stud &amp; EZOut removal on one head</td><td class="s3">118</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">New steel powdercoated head studs</td><td class="s3">386</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">New head washers and bolts</td><td class="s3">186</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">6 sets of rocker retaining hardware (bolt/cup/nut) to replace questionable ones</td><td class="s3">84</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Helicoil kit for 6mm x 1.0 engine shroud bolts that snapped</td><td class="s3">30</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">6 new intake barrel nuts to replace questionable ones</td><td class="s3">42</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Extra 6mm engine shroud bolts</td><td class="s3">5</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">VR head set - gaskets</td><td class="s3">209</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Exhaust studs and nuts</td><td class="s3">75</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td class="s4"></td><td></td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s6">Total</td><td class="s5">1265</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td class="s4"></td><td></td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s6">Optional things I replaced as additional scope creep:</td><td></td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">New fuel lines (all 3 from Len)</td><td class="s3">420</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">New oil S hose</td><td class="s3">23</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">RSR rocker seals</td><td class="s3">84</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">New oil pressure switch at triangle of death</td><td class="s3">5</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Cylinder Head Temp Sensor</td><td class="s3">95.5</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Used 3.2 crossover pipe (old one broke on removal)</td><td class="s3">99</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Summit racing water-based hi-temp engine paint</td><td class="s3">20</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Cam oil return line restrictors - turbo</td><td class="s3">31.5</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td class="s4"></td><td></td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Sport engine mounts</td><td class="s3">48</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td class="s4"></td><td></td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s6">Total</td><td class="s5">826</td></tr></tbody></table></body></html>

Next are the duplicates I ended up with as I either over-ordered due to not knowing what was in the VR gasket kits, or when I changed course to the wrightwood case gasket kit. I bought a Bentley but found it totally superfluous for the engine rebuild. I've used it for other things, so it's not useless, just not needed for this job IMO if you have Wayne's book.

Lastly are the tools I needed to add to the collection. YMMV on these, depend on what you already have!

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{background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:bold;font-style:normal;color:#000000;text-decoration:none;text-align:right;vertical-align:bottom;direction:Context;white-space:normal;overflow:hidden;border-right:;border-bottom:;} .tblGenFixed td.s6 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:bold;font-style:normal;color:#000000;text-decoration:none;text-align:left;vertical-align:bottom;direction:auto-ltr;white-space:normal;overflow:hidden;border-right:;border-bottom:;border-left:1px solid #CCC;} .tblGenFixed td.s3 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:normal;font-style:normal;color:#000000;text-decoration:none;text-align:right;vertical-align:bottom;direction:Context;white-space:normal;overflow:hidden;border-right:;border-bottom:;} .tblGenFixed td.s4 {background-color:white;font-family:arial,sans,sans-serif;font-size:100.0%;font-weight:normal;font-style:normal;text-decoration:none;vertical-align:bottom;direction:Context;white-space:normal;overflow:hidden;border-right:;border-bottom:;border-left:1px solid #CCC;} </style><table dir="ltr" border="0" cellpadding="0" cellspacing="0" class="tblGenFixed" id="tblMain"><tbody><tr class="rShim"><td class="rShim" style="width:0;"></td><td class="rShim" style="width:334px;"></td><td class="rShim" style="width:120px;"></td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s0">Parts I bought but didn't use/didn't need:</td><td></td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Small end rod bushings (machine shop said old ones were too good to replace)</td><td class="s3">33</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">VR case gasket set</td><td class="s3">55</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Extra set of valve stem seals (came with VR head set)</td><td class="s3">24</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Extra set of cylinder base gaskets (came with VR head set)</td><td class="s3">34.5</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Oil pump lock tabs (included with wrightwood kit)</td><td class="s3">13</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Rear main seal (included with wrightwood kit)</td><td class="s3">21</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Bentley manual</td><td class="s3">103</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td class="s4"></td><td></td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td class="s4"></td><td></td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s6">Tools I added:</td><td></td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Sandblasted engine shrouding/air guides/valve covers (bought sandblast cabinet)</td><td class="s3">180</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Cam holding tool</td><td class="s3">78</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Engine stand yoke</td><td class="s3">45</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">How to rebuild a Porsche 911 engine book</td><td class="s3">25</td></tr><tr dir="ltr"><td class="hd"><p style="height:16px;">.</p></td><td dir="ltr" class="s2">Clutch alignment tool</td><td class="s3">9</td></tr></tbody></table></body></html>

VERY helpful posts
 

Thanks for fully documenting this thread and continuing right through to the end.
This is the sort of information which makes this site invaluable to 911 owners.

For example, your SNAFU with the big-end caps is a clear lesson to me to be careful there with my own rebuild. The listing of up-to-date costings is also extremely helpful for reference & comparison - I have already made some decisions using this info.

Peter in Melb.

Great project, well done.

I'm doing the "inverse" (top end and piston rings, no case splitting) and I have a little tiny question for you - what triggered you buying new rocker arm hardware and where did you buy your Wrightwood kits from?

I bought the rocker arm hardware because several of my old sets were rusty and the Allen heads were slightly rounded...I was concerned about being able to torque them down.

I don't want to be disrespectful to our host, I'll PM you on the kits

Great thread, very timely for me. With the help of a fellow Pelican who has rebuilt a few 3.2s, I'm tackling an 86 with 7 broken head studs this winter. Since it has 150K on it, we are almost certainly splitting the case and going all out.