1977 2.7 Engine rebuild!

[911Shoes]

I have always Loved the looks, the great performance and handling of a 911. I searched for about 6 months to year until I found the deal/ car that caught my eye. I purchased a 2.7 911 Wide body with 73k miles in March of 2012 from a gentlemen in Maryland. Driving this car home to Virginia was a dream! I am very pleased with my purchase. I noticed before I purchased the car that it was leaking oil "common problem" The seller clearly expressed that. I figured I would drive the car until I ran out of the keg of oil that was given to me at the time of purchase. Then after would follow a engine rebuild! The car was mechanically strong at the time of tear down and ran flawless! Minus the oil drops that seemed to follow and the annoying smoke that would end up from the oil dripping on the exhaust headers Before the rebuild process I decided to repaint the car and replace the the carpet!

The rebuild took place at 76,500.

Find a reliable, knowledgeable rebuild-er. After doing plenty of searching I found rennsport systems! Reading nothing but the best reviews I figured I could sleep good at night trusting them with my engine rebuild!

Engine goals:

A safe reliable 230 hp!

Speaking with Steve at Rennsport Systems he gave me a list of safe practices and procedures to follow on getting my engine where I would like it to be. His knowledge on these cars is astounding!! I know I have my engine in great hands. I tore down the engine and had it shipped to him where everything will be sorted out machine work will be done and a complete rebuild will go underway. Continue to follow as I will list my engine modifications and progress along the way!

[Discseven]

Great project! Tail was a nice addition ~

[manbridge 74]

Nice car.

Any chance you are from the Toyota MR2 world? Your location and evident skills seem familiar.

[JmuRiz]

Cool project, I'll be watching this thread. I have a '77 2.7 and when/if I need to rebuild I'll probably use this to guide me.

[Lapkritis]

Good luck - I'm doing a similar job with mine and will look forward to your updates for comparing notes.

[911Shoes]

Originally Posted by manbridge 74

Nice car.

Any chance you are from the Toyota MR2 world? Your location and evident skills seem familiar.

No I have owned a few Honda S2000s and a NSX I had some friends tear down the engine with the help of me, handing them tools and bagging screws and bolts for them!

[O' yeah"74]

Very nice, look forward to seeing more.

[irobertson]

Nice looking car. I'm planning on the same front bumper. My body work & paint is going to have to wait though. I'm just starting to put my 3.2 back together.
I'm going to refresh the suspension, drive it for the summer, then get the body done over next winter.
Do you have any shots of the rear of the car?

cheers

[911Shoes]

Thank you for all the positive feed back. I'm In the process of removing the front oil cooler now and all the hard and soft lines to clean them for the long-ability of the rebuilt engine! I have more pictures on my fb here Facebook If these pictures don't work let me know and I'll Find away to get them up

[911Shoes]

[nick91182]

Did you install the side mirror or were they already there? I've been looking to replace my stock mirror to a rs look. Let me know

[911Shoes]

I replaced the mirrors! Changing the mirrors is as easy as changing the wiper blades, all you need is some time and a hex key

[red 2.7]

Hi I'm looking forward to your rebuild. I also have a 77 2.7 Mine has a top end build only with new rs pistons and cylinders E cams and PMO carbs it is fantastic. Plenty of power and very smooth with no flat spots. 235 hp is possible how are you going to achieve it? I have been a customer of Steve's for a few years he's great.

[911Shoes]

Since I have been waiting on the engine I have ordered some goodies!

New oil lines back to front, New center mount oil cooler and a new thermostat


Replaced the headliner



New rear window seal on the way, As it got a little chewed up when I pulled the rope around the seal Sure thats going to leak!
Replaced the carpet




Replaced the front carpet




More coming soon!!!

Thanks to elephant racing for the oil lines from the tank forward and back!
Pelican for the headliner, trunk carpet and interior carpet!!!

[911Shoes]

More Pictures and up dates

Finishing up the oil lines! Thank you Elephant racing, This was a easy to install and very well assembled cooling kit!!





Test fitting the front mount cooler

[911Shoes]

Changed the gauge lights to leds Purchased from Etarga here on pelican. These were very easy to install and really made the interior lights come back to life!

Carefully pry out the gauge

The instructions will show you where to pry out the old bulbs and how to replace them

Time to let them glow! Before is on the top

[911Shoes]

Ordered some parts soon to install

Msd 16al, Msd High Vibration coil and Magnecor wires!

Thanks Rennline.com - Porsche Performance Parts, Accessories & Race Parts for Porsche, BMW & Audi for the battery relocation kit!

This kit involves exteding the batery cable to the smuglers box along with installing a new ground point on the stearing coloum!
Waiting to install these soon before the delivery of the engine



Red wire is the power wire to the amp under the passenger seat powering two 8 inch subs for a little extra sound! (the cables are just laid about for the moment)

[911Shoes]

I was also informed to replace the gas tank or to have the old one cleaned and resealed along with replacing the fuel lines front to rear, Thus preventing clogging up the Carbs!

New fuel tank from Porsche


Draining the fuel tank from the drain plug located at the bottom of the tank using the head of a 3/4th spark plug socket and an extension, No special tools here... YET!


Closely examining the fuel lines from the fuel pump to the rear I noticed the lines were damaged! Fire hazard saved! Thanks Steve . Examining and replacing of the fuel lines is something I strongly suggest! This job was pretty easy after removing the transmission for better access to the fuel lines at the end of the tower!

This is viewing the pressure and the return line at the fuel pump between the two front wheels, looking closely you will notice ones damaged

Removing the fuel pump is easy, Remove the two wires under the rubber boots, each wire has a different sized pole and different sized Mm nut, these two can not be hooked up wrong. Disconnect the fuel lines also unscrew the clamp holding the fuel pump, slide the pump out of the way. Place the pump in a baggie to prevent grit from getting in the system.





Disconnect the fuel vdo sending unit and also all other hoses connecting the tank to the filler, unscrew the 3 hex head screws clamping the tank to the body. The tank should then be free to remove from the top!



After the tank is removed now is a good time to replace and repair any sheet metal damage in the front of the tub.

[911Shoes]

Cleaned Oil tank prevents old crud from getting into the oil system that can wipe out bearings and cams. Thanks pacific Oil Cooler Services Pacific Oil Cooler Service, Inc. - Home Thank you


Returned after cleaning, Be sure to order a new gasket for sealing the oil level unit to the tank and all other hardware.

[911Shoes]

New parts soon to be installed
New fuel lines w/grommets
Bosch fuel pump
Clutch cable
Rennline block off plates
Pedal Bushings
Sunroof seals
Inner + outer shift coupler boots
Rennline blower motor cover
Rennline block off plate
Dual deck lid shocks