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Yes, I made the mistake of misreading the gap gauge. My bad! All fixed.
The long block is now sealed and I'm putting on the exhaust and with a little luck I'll be able to have that done today as well. I spent a lot of time today doing the final cleaning on the valve covers. Here's what I did: I started with the valve covers that I took down to the shop and ran through the parts washer. I think I did probably 5 or 6 cycles on those things. I decided to go with the natural aluminum look on the valve covers. I ordered the paint prep and the aluminum prep from Eastwood. http://images.tapatalk-cdn.com/15/05...98d3175099.jpg http://images.tapatalk-cdn.com/15/05...39774524e7.jpg This is what I started with: http://images.tapatalk-cdn.com/15/05...0b3b7e1cf2.jpg The instructions are to apply a coat liberally and wait 3-5 minutes and then buff to finish. Repeat as many times necessary until desired results. I think I ended applying 7 coats with some brass brush and scouring pad buffing and even a Mr Clean wipe as a final finish. http://images.tapatalk-cdn.com/15/05...afda513cf9.jpg http://images.tapatalk-cdn.com/15/05...91edae3b32.jpg Making progress http://images.tapatalk-cdn.com/15/05...624c8064b0.jpg A lot of elbow grease later, this is where I stopped: http://images.tapatalk-cdn.com/15/05...70a800eee4.jpg |
Lookin good!
Next time you might add up all the money and time and consider having them glass bead blasted. It's a lot less work but the reality is, you did it yourself and there is some intrinsic motivation when you can say that!! Heres a set I did Friday night for a customer with a turbo for comparison. No special chemicals, just some quality time in the blast cabinet with good music on the headphones. http://forums.pelicanparts.com/uploa...1433107999.jpg |
You're right JB, there is a lot of motivation in being able to say I did it myself. Last night I spent some time with the blast cabinet at the shop after work removing the paint on the engine mount bar prepping it to be refinished. I will spend some more time blasting atleast another piece of engine tin getting it ready for refinishing today. The trouble I find in this whole process is being able to find some quality time to do these little projects that end up eating up so much time. Although it has been frustrating at times, I have enjoyed this process since I started it. If I had to do it over next time, I probably would have expanded my tools and parts list before getting started. There have been various delays because I had come across something that I needed to do but was unable to move to the next step because I did not have such and such tool or because I did not know that I should replace "X part" while I was at that point and had to stop progress to either go buy or wait for something I ordered to be shipped. That has probably been the number one frustration during this whole thing. I have to admit there have been a number of times where I was thinking I should have never taken the damn thing apart. But I kept pushing, I'm getting close and it's good timing too because my car is almost ready. I can't wait to get back to the track this summer.
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I agree with your concern. When glass blasting any part it is imperative to clean it very well prior to reassembly. Your scare tactic is a little over the top though. I think a little common sense is just what the doctor ordered. Thorough rinses and good, sound cleaning processes should be in place before putting any part back on regardless of method used to clean it. Brass and steel brushes can leave bristles and scotch-brite pads leave little green hairs that would also be detrimental to bearing shells, oil squirters or any other number of small orifices that require clean oil. Bead blasting is no more risky than those methods if a good follow up cleaning process and inspection is not performed.
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Bead or sand blasting will imbed particles in the metal that will not be removed with a thorough cleaning, but can be released over time. Why run the risk, when there are other methods of cleaning, that have no risk.
No scare tactics here, just well proven facts. |
Hmm... I'll be your huckleberry. Since you told everyone what not to do, how about you offer advice on what to do. I'm always up for learning something new. Let's hear it.
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I am very sorry if I offended you., why don't we just leave it at that.
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No offense taken here! I'm genuinely interested. Over the last few months I have tested a few different chemical processes and they haven't worked out well. I've tried alum-I-brite and alum-a-brite and some other magical liquids. They tend to leave a dark, mottled finish and do nothing to get good clean gasket surfaces.
I would love to know what can be done, besides low pressure bead blasting with very expensive glass beads to ensure that nothing embeds itself in the metal. And then the 30 or so minutes of cleaning, rinsing, blowing and repeating that process two or three times to ensure the surface is sufficiently cleaned. All before lapping the sealing surface. Please share your method. |
Baking soda blasting cleans pretty good and doesn't leave any abrasive silica powder or nuclear fallout behind:)
Whatever is left on the parts dissolves and rinses off with water. |
Jim, I have the conversion kit for soda in my tool drawer. I was hoping to see some pics somewhere of how the soda ends up making the parts look. It would be awesome to just rinse the parts. I know that a few of the left coast guys swear by soda but I haven't really seen any pics that show sparkling parts after they are done with the process. Do you have any pics you can share? Is it aggressive enough to make for a nice gasket sealing surface?
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I have been waiting so patiently to get to this point, I really feel like I am getting close.
http://images.tapatalk-cdn.com/15/06...7064afb0be.jpg During the installation of my nearly new SSIs I came across this on one of my super trick ARP Racing manifold studs http://images.tapatalk-cdn.com/15/06...a14f8814b1.jpg I emailed Troy at EBS Racing (my salesperson at EBS) this pic on Sunday and today a replacement spacer arrived. Please keep in mind I bought these from him last summer and had him ship them directly to Anchor Atlantic in NJ where my heads were being done. Lots of ???s along the way about what could have happened, his reply to my email "I'm sending you a replacement". I would totally buy from them again, hands down!! |
"No offense taken here! I'm genuinely interested. Over the last few months I have tested a few different chemical processes and they haven't worked out well. I've tried alum-I-brite and alum-a-brite and some other magical liquids. They tend to leave a dark, mottled finish and do nothing to get good clean gasket surfaces.
I would love to know what can be done, besides low pressure bead blasting with very expensive glass beads to ensure that nothing embeds itself in the metal. And then the 30 or so minutes of cleaning, rinsing, blowing and repeating that process two or three times to ensure the surface is sufficiently cleaned. All before lapping the sealing surface. Please share your method." Soda is the way to go. When done spray the part with vinegar in a spray bottle then rinse with warm water, done. Absolutely no chance of contamination. A cabinet blaster can be set up to use soda. |
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This thing is really starting to come together. I just wish I could take a day and just finish it. I guess that why they call them projects, you fit it in when you can. Kinda like a work in progress. Looking more like an engine every time.
http://images.tapatalk-cdn.com/15/06...deb1082c75.jpg http://images.tapatalk-cdn.com/15/06...8449f2653f.jpg http://images.tapatalk-cdn.com/15/06...0b3ab6a817.jpg I ended spending a couple of hours bead blasting the alternator housing and fan, the time investment was completely worth it. Now comes the second parts I feel intimidated by...wiring harness and intake. Good thing I took the time to take a ton pics before I took it apart. |
Better clear coat those parts or they will oxidize again pretty fast.
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Thanks, I appreciate the compliment. This has been the most fun I've had being frustrated because things at times have not gone the way I laid them out in my head but I am very proud of what I've done. I know it's not professional race shop quality or show car pretty but I did it and to me that's all that counts. I would not trade this experience for the world because I will now have even more appreciation for my machine especially when I'm on track.
Here's where I stopped last night http://images.tapatalk-cdn.com/15/06...372b6d2646.jpg http://images.tapatalk-cdn.com/15/06...1c8b1752e9.jpg http://images.tapatalk-cdn.com/15/06...f64c9065b7.jpg http://images.tapatalk-cdn.com/15/06...d4aa3a4564.jpg http://images.tapatalk-cdn.com/15/06...5496aefa87.jpg Plan is to finish installing the intake and get the fuel lines and wiring harness all hooked up this weekend. Damn, I am so close!! |
Since I don't see it in the pics, make sure that you hook-up the large ground wire that attach to the engine case.
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3.2l rebuild, the quest for more power
Thank you but I am happy to say that I did not forget to do that. It actually made me a little nervous because when I was tightening the bolt I felt like I was stripping the case bolt and then the torque wrench clicked. Whew!!!
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Can anyone verify for me whether or not I have the fuel lines hooked. I sent the original ones to BoxsterGT and Len convert them to stainless braided for me. The trouble now is so much time has passed since I've received them I do not remember how they went in and all of my pics only show the the fittings and nothing else. Bentley does not show a very accurate photograph either. Please tell me what you think:
This is where I have the left side fuel rail connected http://images.tapatalk-cdn.com/15/06...5a3366dcc0.jpg This is where I have the right side file line routed http://images.tapatalk-cdn.com/15/06...853b1859a1.jpg And this is where I have the right side connected http://images.tapatalk-cdn.com/15/06...35391a9f98.jpg And this is where I have the fuel line on the back side of the engine http://images.tapatalk-cdn.com/15/06...7c0418a7df.jpg I feel like I did it right, but could someone please look at this and let me know what if anything I did wrong? Thanks in advance |
Very productive weekend. Engine tin modified and fitted for the heating backdate. This turned out to be quite the task since I was changing the configuration but keeping the a/c compressor. I didn't realize how much stuff was going to have to be installed, removed, reinstalled again, removed again. It felt like a never ending process.
http://images.tapatalk-cdn.com/15/07...7491bc0df2.jpg http://images.tapatalk-cdn.com/15/07...d3687e9ccd.jpg I must have taken that air tube off four or five times. Between routing of the plug wires, the a/c compressor bracket that bolts above the right upper valve cover and the a/c bracket in front of the tubing, it was quite the tight fit and I will probably come apart with it atleast one more time. And then there was the modifying of the engine tin to fit for the side panels to allow for the air tubing and the back panel to fit in between the head and the near new SSI's. http://images.tapatalk-cdn.com/15/07...87005441e4.jpg http://images.tapatalk-cdn.com/15/07...9b5771decf.jpg http://images.tapatalk-cdn.com/15/07...057438980f.jpg http://images.tapatalk-cdn.com/15/07...83a91f1158.jpg http://images.tapatalk-cdn.com/15/07...18b988835d.jpg One more clean up http://images.tapatalk-cdn.com/15/07...4c19368aa0.jpg And finally get to painting. I ran out just as I was finishing up on the second coat. http://images.tapatalk-cdn.com/15/07...907287457c.jpg I still have the back panel to do. The ends were starting to crack just inside where the nuts were so I want to have that welded first so I will take it to the shop tomorrow and get one of my techs to weld it for me. Plus I'm not sure what I'm going to do with the big hole. |
I have two 3.2L builds I've worked on that upped power via 3.4L upgrade, one was single plug other was a twin plug. I provided the MAF conversion and tuning services for both of these engines. You can find details on both builds here:
Single Pug 3.4L http://forums.pelicanparts.com/porsche-911-technical-forum/851912-my-87-3-4-maf-project.html Twin Plug 3.4L http://forums.pelicanparts.com/911-engine-rebuilding-forum/871561-1985-3-4-build-using-maf-279-56-hp-237-63-rwhp.html The single plug engine pulled about 249HP at the wheels The twin plug about 280HP at the crank Neither was cheap to build but these are significant, reliable gains over a stock 3.2L |
Sorry for the lack of updates, workload has been intense and I have been trying so hard to get the engine finished. It seemed like the same routine over and over, I'd have good intentions in the morning while on my way to work. I'd think..."okay, I'll get such and such done when I get home tonight", well the day would get going and then I'd have dealt with so many other people's car problems and trying to help them fix their lives (the daily life of a service advisor is both very stressful and extremely rewarding on so many levels) that I would be so mentally drained by the time I get home the last thing I want to do is to mess with my own engine.
I have managed to actually get this thing completed, along the homestretch there were a lot of challenges in doing the heating backdate that made me have to lose the a/c which I was really hoping to keep but since I never use it, I figure it lets me keep the overall look I was going after, and "lighter = faster" in having no compressor, brackets and condenser. This was one of the toughest parts, getting the ignition wires routed to fit around the air flow tubes for the backdate. The tubes get in the way of the original wire path and they are not quite long enough to route in the same path so you have to be really creative in how it's done. http://images.tapatalk-cdn.com/15/07...177299b4af.jpg http://images.tapatalk-cdn.com/15/07...623fd7aab5.jpg I must have fiddled with it and messed with different configurations, taken the ducts outs put them back in a bazillion times. Probably one of the most frustrating things about the whole rebuild. In the end, this what I ended up with http://images.tapatalk-cdn.com/15/07...6273303890.jpg http://images.tapatalk-cdn.com/15/07...788cbf8073.jpg The other side was just as challenging, especially with the a/c bracket in the way and the Sceet filling up any of the smallest of gaps. Thursday evening, myself, my wife and two of my neighbors took the engine off the stand and loaded it into the back of my Takoma so I could take it down to the shop that has my car for it to be gone through to double check my work and to install it into my car. The Porsche gods were smiling on me from ear to ear because Washington D.C. traffic yesterday morning during rush hour even with all the construction on I95 was next to non existent the entire trip all the way to Richmond and back home. With a little luck, I will be burning gas in the next month or so. |
Great work Mike. I have enjoyed following your quest for more power. Could do without the "thread hijackers" but I guess everyone has an opinion and feels they must post! Enjoy!
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Thank you and you're welcome. I have to admit this has been by far the biggest challenge I've taken on with my car in the 10 years I've owned it. I tried to post about real situations that regular guys come up against in doing this while at the same time trying to make their money go as far as it possibly can without giving up on quality of parts or when having to sublet work to someone like Dema Elgin of Elgin Cams or Bob Hirsch of Anchor Atlantic for the machine work on the heads. I may be as finished as I can be and when I get the report on the engine after being checked by the shop I left it with I'll report as to how I actually did. Until then, thank you yet once again to everyone that contributed to my rebuild and to those of you who advised me along the way as I struggled with certain things that I now understand much better having now gone through it. I genuinely appreciate all of you and your guidance.
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I got the report back from the shop that has my engine. They have gone through it to double check my work, installed my engine back into my car and the damn thing actually works. Who would've guessed!! Here's a portion of the report Robert sent me:
"Left bank wasn't timed correctly but the right side was close. Valve lash on all cylinders was loose but everything, cam gears, rocker shafts, timing chain ramps were all torqued and properly installed. Passed the initial 20 min break-in-run-in, the engine runs well and there are no leaks" I realize that is only the short version of what he had to do to get the engine running as I'm sure there are quite a few things he had to do on my engine before he had it running that he is not telling me but damn, I am still having a hard time believing that I actually took that thing apart and got it back together and that it really does work. I am so anxious to hear the exhaust and see what the engine sounds like when the cams come on to power. I am so close to having my car back in my garage, I can hardly wait. |
Here's a couple of pics:
About to go in http://images.tapatalk-cdn.com/15/08...a8d631cc43.jpg Going in http://images.tapatalk-cdn.com/15/08...7eb4af9b53.jpg http://images.tapatalk-cdn.com/15/08...008be20a35.jpg It's in http://images.tapatalk-cdn.com/15/08...7110d330a4.jpg http://images.tapatalk-cdn.com/15/08...f13490a197.jpg Won't be long before I'm burning gas again. |
Very nice. I have enjoyed this thread a lot.
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Cairo, I'm glad you have enjoyed my rebuild up to this point. Hopefully it has been helpful to someone else who has been planning something like what I did and will be enough to give them the confidence to take that first step and keep going towards the engine in their mind with their own rebuild. The thing the I appreciated most was that everyone knew I was a first timer and they were nothing but helpful during my whole experience.
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Looks great. I just got mine back together and running in May, with oddly enough, almost the exact same upgrades as you.
I had to ditch the 2-1 M&K though... it was too raspy and was damaging my hearing. Maybe it's not so bad from inside a coupe, though. |
Did you fire it up yet?
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"Passed the initial 20 min break-in-run-in, the engine runs well and there are no leaks" |
First congrats on taking this project on and how much you've achieve.
I have one question, are you expecting 345 hp just by utilizing a 964 cam and SSI ? Thanks in advance for your reply. |
First congrats on taking this project on and how much you've achieve.
I have one question, are you expecting 345 hp just by utilizing a 964 cam and SSI? Thanks in advance for your reply. |
Sorry for duplicate posting. ...slow Internet connections.
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