P/C install: Easy, install piston to cylinder on bench. Install clip using circlip injector with or without studs in place. The injector makes that the easy, fool proof part.

Hardest/worst part? Fixing stuff other people have screwed up in the past.....

Circlips are the worst! I have a factory tool for installing 964 circlips but for the other motors I have to do it the hard way.

I don't do it enough to get good at it. Every time I do circlips, I know that I figured it out the "trick" on the previous motor but I'm just senile enough that I can never remember *how* so I have to relearn the trick all over again.

When you remember/figure the trick for getting JE circlips out be sure to let me know.

Cleaning, followed by a couple of the rocker bolts (1 and 4 if I recall) I used a hemostat to put the wrist pin clips in. If you grab them in just the right spot, the tips fit into the notches in the piston and they slide right in. Not sure if all pistons have those notches though.

Get a circlip injector!!! Easy!!!! A couple of seconds to install each one. Saves you the trip to the ER for stiches like I did a few years ago.... (you can search for the pictures)

Chris, good see you back on the forums!

Getting them in with the injector is indeed a piece of cake. Getting them out is a study in frustration. Good tool to have is a STRONG pointy pick and some needle nose pliers

That said, I really don't understand why these clips can't be the internal retaining ring type that you can easily removing with retaining ring plies?

ID circlips have those little extra tabs which have mass.
If the clips are in the wrong position...as the piston goes up and down the weight of the tabs loosens the clip in the groove and lets the circlip fall out.
I prefer Spiralocks myself...yes they are a total B**ch to get in and out...but I have never had one pop out at the wrong time (even in an engine blow up).
Bob

Ah ha. Makes sense that at very high speeds the weight of those ID tabs can cause the circlip to flex. Thanks for satisfying my desire to have ID clips in my pistons Bob!

I removed one of the JE clips using a screw driver that I ground down (only had to take one out to go back a step in the assembly). The pick tools would flex and slip no matter how hard I pressed... I tried a half dozen before deciding I needed more lever due to the strength of the clip. I wonder if the JE techs have a tool or recommendation.

as others said, that cam sprocket alignment is really annoying. I also did not like the cam timing. I got mine right but I never really felt comfortable with the process.

circlips are the worst. Cleaning sucks a strong second.
Before I buy the circlip injector will someone confirm that it gets in the wrist pin hole with the cylinders over the studs? Cause they way im doin it now either results in blood in my motors or the need for a ton of extra clips. Ping!! there goes another one. gettin sick of that.

Scott - the home made circlip injector from Home Depot motorsports works perfectly over the deck. Makes the job a matter of seconds as they clip straight in. Link above... under $20.

Awesome. ill give that a try.

Installing piston circlips.......
 

I figured out a way to install the second clip when adding the piston/cylinder assembly to the block. Using some small gauge wire, I place a small screwdriver blade against the bottom of the circlip opening. Then, I engage the top side of the clip into the slot holding it in place with the index finger on my right hand and then use a second flat bladed screwdriver to slide the opposite side of the clip up the flat edge of the first screwdriver, using it as an inclined plane. This causes the clip to compress evenly and snap into place in the piston. Last step is to make certain that the clip is properly seated all the way around. The screwdriver that is used to push the clip into place has a small notch ground into the blade so that it won't slip off the clip and draw blood!

http://forums.pelicanparts.com/uploa...1377790527.jpg

http://forums.pelicanparts.com/uploa...1377790625.jpg

Actually, I had purchased a circlip injector tool from PP for this build, but it turned out that the Mahle pistons I had required 23mm pins instead of the 22mm ones. The 22mm tool will not work with the 23mm clips! I probably could have returned it for the other size, but the next engine just might need the 22mm one.

I too used the homemade circlip injector that I learned from Ed Hughes over on Rennlist. It is very easy then.

In terms of the job I found hardest, I would say it was assembling the case halves. Nothing specific about it was that hard, but it is a very time bound operation and you need to be really organized. There are many ways to make mistakes and you don't have a lot of time to "think" once you are on the sealant clock.

Everything else in an engine build can move as slowly as one needs/desires so you have the luxury of checking, pondering, re-checking and then re-checking again!

Cleaning was the least fun part.

+1 on CLEAN-UP.

I don't remember the circlip being that bad, have only done it once.
I grabbed one end of the circlip with pliers and engaged the other end in the grove and twisted it in pushing with a finger on it. If it slipped my finger would catch it.

Magnus, I'll bet you're talking about stock circlips. The JE clips are about twice the strength as a stock clip and far more difficult to install because they do not want to bend. Personally I don't think there's anything all that difficult with a 911 assembly; pretty standard fair. Cleaning the parts to what is deemed appropriate is the most time spent and a lot of it is over-kill. Clean is clean but making a part that you will never see again look new is over the top. I really like over the top.

Finding time to do the work. haha