3.2l rebuild, the quest for more power

[911pcars]

Originally Posted by michael lang

It's a relatively thin layer, probably between .25-.5mm thick at its thickest point. Yes Sherwood you are correct, it was a perfectly running when I took it out before I took the body down to be repaired.

Somewhere along the slippery slope, one must decide how far to go. A few hundred here and there and before you know it, you have a busted budget. Go with your comfort level.

Sherwood

[michael lang]

Isn't that the truth. I was just talking about it last night with my mother in law. I feel like I am making progress but because this is my first time doing this I feel like I am at times feeling my way through it.

[safe]

I used something called "carbon remover" that I soaked my pistons in. After a night in that the carbon could be rinced away with a stiff brush.

[michael lang]

After doing some online searching and looking around the forum it lead me to Chem Dip.



Lots of really good reviews, even found a you tube video of it so I bought a gallon.
This is what I started with





This is after about 4 hours soaking



I used a brass bristled brush to remove the excess cake on the top of the cylinder and let it go for another few hours. This is what it looked like after I let soak overnight



Before we opened and my day got out of control I taped up the sides of the piston to help protect it and put it in the bead blaster this morning. Here's what I ultimately finished up with and I think it is clean enough to stop and get these things put back in.





If I can get all six looking that I will be more than thrilled at my results. I have a feeling this is going to be a good day.

[911pcars]

Originally Posted by michael lang

After doing some online searching and looking around the forum it lead me to Chem Dip.....................

If I can get all six looking that I will be more than thrilled at my results. I have a feeling this is going to be a good day.

Good job.

In my first post, I was going to add a story about Steve Jobs about a lesson he learned from his Dad rebuilding a fence, but Jobs, as brilliant as he was, turned out to be too anal and verbally abusive toward others to impart any lessons to anyone.

Sherwood

[Mr Beau]

Have you measured the ring lands and piston skirt for wear?

[michael lang]

Thanks Sherwood, I really appreciate the compliment, hearing that from you makes me think I am headed in the right direction. The final picture is what I envisioned that I wanted going back in my engine as I reassemble it and it feels very satisfying accomplishing that goal.

Matt, I really didn't measure those things, I didn't think I needed to since I had the sides of the piston taped and fully protected from any bead getting to the sides or inside the piston where the wrist pin goes. Plus, if you look at some of my earlier pics I had already put the cylinders over the pistons only to take them off because I was worried I broke a ring. Anyway, Matt, they were tight tight tight so I feel I will be fine on that. Was there something I should be looking for?

[Mr Beau]

Mike,

I was referring to wear that happens when an engine runs. Ring lands become wider, so you can end up with too much side clearance even with new rings. And piston skirts wear/bend which causing rocking, also hurting ring seal. While yours look fine it may not hurt to have them measured up. While you're in there...

[911pcars]

Originally Posted by Mr Beau

Mike,

I was referring to wear that happens when an engine runs. Ring lands become wider, so you can end up with too much side clearance even with new rings. And piston skirts wear/bend which causing rocking, also hurting ring seal. While yours look fine it may not hurt to have them measured up. While you're in there...

Sorry Mike. Mr. B is right. Better to have confidence the engine won't need reopening for another 100K + miles .....at least for rings and/or pistons. Shouldn't cost much to have a skilled machinist double check for you. Bring specs and your pistons/cylinders//rings. Prep a chart so the can record measurements, e.g. piston/cylinder number, piston-to-cyl. clearance, cyl. dimensions, ring lands 1-2-3 x 6, etc.

Sherwood

[michael lang]

My rings came earlier this week and because I knew I had a heavy workload this week I figured I would spread the "decarboning" of the piston tops a couple at a time. Happy that all 6 came out perfect as perfect could be. I was expecting installing the rings to be more tedious and time consuming. Couldn't have been easier. Clean the slots, clean the rings, wipe down the tops install the three rings. Take your time and be very aware of the tension on the ring as it is being slid over the piston top and into its correct slot.







Now for the hard part... getting them back into the cylinders. Goal for the weekend is to have the heads/cam tower installed.

[mreid]

Did you install the rings in the cylinder and measure gaps first? Always a good precaution so you trust yourself and not someone else.

[911pcars]

This YouTube series is good for an overview of engine assembly. There's no one "right" way to do it, and it's interesting to see how others tackle this and the steps they take to ensure correct assembly.



Hope this helps,
Sherwood

[michael lang]

mreid, to answer your question, yes and no. I did install them into each of the cylinders to check for fit but since I do not have the correct measuring tool I do have the spec. I only used a flashlight on the opposite side of the cylinder to see if light came through between the cylinder wall and the piston ring. The light from inside the cylinder drowned out the pic so I don't have one to post but based on what I had yesterday, I think I will be okay. I thought the first time I put the pistons inside the cylinders was difficult, this time it will be damn near impossible. Those brand new rings are tight!!

[safe]

You really need to check the ring gap, do not trust that new rings are OK. If they are to tight you could be in trouble...
The tool is cheap and available at most places that sells tools.

With the right ring compressor it should not be very difficult to install the cylinders over the pistons.

[Mr Beau]

A 'ring gap checker' is just a feeler gauge... Putting the rings in a cylinder and checking the end gap is probably the easiest part of the whole process. No reason not to. If you get fancy you can check the gap at various locations in the bore as a check for cylinder taper.

[Jcslocum]

Mike, you need to check the end gaps of the rings and file those that are too tight. You do not need a special tool to do this, although they do make a ring file tool. These are really small gaps and if too tight will destroy the cylinders in short order. Too loose will just give away compression and low power is the result.

I have a really good ring compressor if you need to borrow one.

[michael lang]

Jon, thanks for the offer. I stepped up and bought the Hazet ring compressor. I have to admit, for such an expensive tool I thought what the hell and am I going to do with that thing and I hated it at first, I thought it was awkward, did not do a good job of compressing the rings and took forever to get the piston inside the cylinder which is why originally I thought I broke a piston ring. That was the first time I used the tool. Then I took the cylinders and pistons back apart to replace the rings. The second time, I figured it out. I was able to install all six in about an hour or just under. The problem was I did not understand what the trick was for setting it up. I got it now.
I took the time to measure all 18 rings in each of their perspective cylinders. All 18 are good and within spec. I did it just like Wayne's book suggested. Inserted piston in through the bottom and put each of the three rings in through the top starting with the bottom ring first. Checked the end gap and side gaps. All within .3mm so I went back together with it.
Now comes the part that I have been not looking forward to, I have read and read about setting the timing but for some reason, I just can't seem to visually see how the setting the timing comes together. I'll just have to jump in with both feet once I get the cams installed. I'm sure I'll be posting some very elementary questions so please forgive my inexperience with I'm sure some really dumbs questions in advance.

[Jcslocum]

Mike, Allie lives in DC if you need a second set of hands and someone to read the manual as you go. She will be doing cam timing next weekend on her 3.4 project if you want to wait until that is done, she will have 1 time experience. As long as your not some kind of white van serial killer or stalker with a record it would be ok.

[fred cook]

Considering the overall cost of a rebuild, I decided to spring for a hardware kit from PP. Having all new, clean, etc nut, bolts and washers helped make for a better final product.

[JJ 911SC]

Originally Posted by Jcslocum

Mike, Allie lives in DC if you need a second set of hands and someone to read the manual as you go. She will be doing cam timing next weekend on her 3.4 project if you want to wait until that is done, she will have 1 time experience. As long as your not some kind of white van serial killer or stalker with a record it would be ok.

By any chance, does she have her Passport

Of all the offers I have seen on PP this is it