Rod caps
 

Stretch Gauge
 

Here's a review I did using my Summit Racing stretch gauge - similar to the one in your picture.

Has a few tips I figured out to help get accurate readings (mine requires 2 hands to manage as well)

http://forums.pelicanparts.com/911-engine-rebuilding-forum/789996-summit-racing-rod-bolt-stretch-gauge-review.html

Meanwhile, I'm sure you will be fine torquing to spec.

Gordo

Rod bolt stretch
 

Ok, so I read the link above and decided that I needed a mulligan. Loosened them all up this morning and worked on the stretch gauge to make it fit as snugly as possible. checked the rod bolt length, zeroed out the gauge and torqued to the spec of 50 lb then checked the stretch. Surprisingly most fell right in range. Three were at .09 and one at .08 so it is a good thing that I checked them. The ones that were a bit loose I put a long breaker bar on (for more feel) and tightened them ever so lightly until I hit the mark. It doesn't take much stretch a bolt one thousandths.

To make the gauge read more accurately I used two hands to hold it on the bolt and pushed the back side of the dial indicator so that it made solid contact with the bolt.

So, all done and I feel a lot better about it.

Prep for case Assembly
 

So it looks like today is the day for assembling the case. Raining out and in the low 70's today so sealants should take a bit longer to set up which is a plus for my first time rebuilding a Porsche engine.

Trying to be as prepared as possible for a seamless (pun intended) engine assembly.

http://forums.pelicanparts.com/uploa...1416672180.jpg

Sealing Case
 

Here we go!

http://forums.pelicanparts.com/uploa...1416684499.jpg

Case sealing
 

Onward!

http://forums.pelicanparts.com/uploa...1416684584.jpg


http://forums.pelicanparts.com/uploa...1416684621.jpg

Ta Da!
 

Short block Done!

http://forums.pelicanparts.com/uploa...1416684915.jpg

Just a few things need to be done to finish. Heads need to be rebuilt along with cam towers and I will need to find the bolt to hold the 964 cams to the chain sprocket since it is different than the SC cam. I also need Head studs and gasket set.

This will happen after Christmas so until then... Merry Christmas!

great progress there tom...make sure to put any & all parts needed on your xmas list...
I hope u can get some other work done btwn now & xmas as I enjoy seeing your progress and great works...thx, bob

Thanks Bob

For what it is worth:

I didn't use any of those special tools to hold the chain or rods. If you use assembly lube the rods will stand up on their own if you work at balancing them and the chain I rolled up and once the case was together I fished it out with a coat hanger that I made in advance with a small hook on the end.

I am sooooo Jealous right now... Congrats!!...I should be able to finish mine in the coming weeks..

Odds and ends
 

Lots of odds and ends to wrap up. Starting with the oil screen and housing. Used 574 on all of the gaskets.

http://forums.pelicanparts.com/uploa...1417202731.jpg

Tom, I wouldn't use any sealant on sump plate seals. That plate will come off from time to time to clean screen. The two rubber seals work fine dry.

Just a tad late for that advice. I will remove it again after break in so I will reseal it dry after that.

Thanks for the advise though.

Sorry. It's no big deal though. Just clean-up. Not like you resealed your case 3 times.

I have to tell you, I was scared to death that I was going to forget something like a pump seal. You really have to read up and triple check everything to make sure that nothing is missed prior to buttoning up.

I still have the urge to open it back up to make sure I didn't miss anything although I am positive that I didn't.

Odds and ends
 

Finished up some odds and ends

Finished up the sump plate and plug

http://forums.pelicanparts.com/uploa...1417372348.jpg

Chain ramps
 

Then finished up chain ramps.

Note that the ramp should barely go past the end of the bolt. There is a small tab near the end of the ramp on only one of the bolt holes. Check it out before you actually put one on so you know how far to push it on. You can push it on past the clip and if you do the groves on the ramps will not line up with the chain causing them to wear out quickly.

http://forums.pelicanparts.com/uploa...1417372587.jpg

Also, the chain ramps long end should point toward the gear.

Short block done
 

So, that's all there is until head studs show up. Then I can put the Pistons and cylinders on.

http://forums.pelicanparts.com/uploa...1417372722.jpg

Bagged
 

So, I went out and purchased one of those expensive engine bags to protect it and keep it clean.

I think Hefty makes them 😉

http://forums.pelicanparts.com/uploa...1417372836.jpg

Nice tread and good job !!!

Back at it
 

Well, finally getting back to it. Head studs came in yesterday and a new Wrightwood head gasket set is on order. I heard too much bad stuff about other gaskets and want to do all I can to avoid leaks.

These head studs are a work of art!

http://forums.pelicanparts.com/uploa...1422047028.jpg


http://forums.pelicanparts.com/uploa...1422047054.jpg

Great thread!!!!!!!!!

Keep up the good work and the updates coming. Love the high value engine bag :-)

ARP Head Studs
 

Well, today the head studs went in. Look at a lot of links on installing them and decided to use a dab of locktite on them. Make sure that you don't overdo it, just a dab near the bottom of the threads will distribute it evenly.



Because of the thread chaser I made (see earlier post) the studs went right in by hand right to the bottom of the hole. Once the Locktite was on I screwed them in all the way to the bottom and then backed them out about 1/4 turn so that they weren't sitting on the bottom of the hole. Once in I used my caliper to make sure they were all fairly even which they were. Just a small turn her and there.

http://forums.pelicanparts.com/uploa...1422111832.jpg


http://forums.pelicanparts.com/uploa...1422111847.jpg

Gasket set should be here Monday so look for piston and cylinder install next week.

Still need to send the heads and cam tower for rebuilding.

Locktite
 

For some reason the picture didn't post

http://forums.pelicanparts.com/uploa...1422112116.jpg

Important!
 

One important thing that I should have posted before locktiting the stud in.

TRIAL FIT THE CYLINDERS AND HEADS TO MAKE SURE THAT THE STUDS PROTRUDE ENOUGH TO GET WASHERS AND NUTS ON!



http://forums.pelicanparts.com/uploa...1422141809.jpg

http://forums.pelicanparts.com/uploa...1422141895.jpg

Nice job !!

Thanks for sharing........

Great thread!
 

Thanks for this great thread. I'm now a subscriber. Just picked up my new project a week or so ago. Yup, broken head studs. This thread will be an invaluable tool for my future endeavors! Keep up the great posts and pics!

http://forums.pelicanparts.com/uploa...1422279163.jpg
http://forums.pelicanparts.com/uploa...1422279200.jpg

Subbed. Awesome thread!

Great read and reference for those of us considering an engine rebuild someday! Thanks!

Heads and cam towers are boxed and ready for pickup by FedEx tomorrow. I sent them to Ollies. Called and spoke to them today, they said box them all up, put a note in the box explaining what I want done along with contact information and they would call once they get everything and can unpack and examine what I have.

Gasket set should be here tomorrow so I am inching closer to finishing!

Cylinder holders
 

Saw cylinder holder tools available but when you only use it once why buy expensive tools? I bought a 2 foot piece of 1/2" PVC and made my own. Cut it with my pipe cutting tool to 1 1/2" and it fit perfect.

http://forums.pelicanparts.com/uploa...1424652271.jpg


http://forums.pelicanparts.com/uploa...1424652296.jpg


http://forums.pelicanparts.com/uploa...1424652331.jpg

Parts will be back from Ollies tomorrow so look for updates soon.

I thought you couldn't hone alusil cylinders??

Honing Cylinders
 

Technically I didn't hone mine. After doing a lot of research I decided to clean them, and then use scotch bright on them. If you search this site you will see a lot of different ways to scuff the cylinders to reuse them. Mine was a low mileage engine and honestly, I didn't have $4000+ to sink into new Pistons and Cylinders so I reused what I had.

I have a 3.0sc with 100,000 on it and I'm wondering what I'm gonna do when I cross that bridge because honestly I don't have $4000 for new ones either. It seems crazy that one piston and one cylinder has to cost $500 or $600 dollars.

For a lot of Porsche guys money is no option. To me it is and I can't just drop 20 grand to build a killer motor so I am building mine on a budget. Honestly I don't have a budget but I am buying parts as I can afford it. I took a 3 month break over the holidays but am back at it. I think all of the big expenses are behind me now.

Had I tried to save the money to buy new Pistons and cylinders along with the extra cash it would have taken for additional machine shop work it would have been a 3 year build.

Parts are here!
 

Heads and cam towers got here today! http://forums.pelicanparts.com/uploa...1424734771.jpg


http://forums.pelicanparts.com/uploa...1424734816.jpg


http://forums.pelicanparts.com/uploa...1424734854.jpg


http://forums.pelicanparts.com/uploa...1424734895.jpg

Cylinder install
 

Got the block ready to receive the piston and cylinder

http://forums.pelicanparts.com/uploa...1424735071.jpg