Cool project. If it was mine I'd probably chop the top and make rear windows to go for a wagon conversion, but I'm kind of weird and think those are cool.

..a pedal car.

http://forums.pelicanparts.com/uploa...1441647814.jpg

Keep your bent rods and twisted levers - this one has sprockets and a CHAIN mister! No pinching or blood blisters with this one - here, your three-year-old legs get devoured by a slow moving chainsaw!

After some light sanding and metal treatment:

http://forums.pelicanparts.com/uploa...1441647899.jpg


(*Actually the chain/sprockets are covered with a metal chain guard.)

http://forums.pelicanparts.com/uploa...1441647951.jpg

Got the engine broken down today. This engine ran strong and was rebuilt 40k miles ago. I am going to change the rods, so I'll get a peek at the rod bearings. I'm hoping the case does not need to be split. All the head studs were intact, even the lower divlar studs. I am replacing them, so I guess there is still time for drama!

The cams with rockers, heads, and p&c's will all be available for sale soon at low prices.

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http://forums.pelicanparts.com/uploa...1443383118.jpg


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Wow, I got really lucky or someone else felt the pain. The studs came right out using the double nut method. The exhaust side divlars were actually easier than the upper steel, but neither required heat. Next weekend I'll check the rod bearings and replace the rods if they are fine. Of course I also discovered that my new cams are the later style with the bolt, while my 78 3.0 uses the large nut. One more tool to buy...

http://forums.pelicanparts.com/uploa...1443393071.jpg

http://forums.pelicanparts.com/uploa...1443393124.jpg

Cleaned up the rest of the engine and installed the Pauter rods. Bearings looked great which reinforced my decision not to split the case.

http://forums.pelicanparts.com/uploa...1443913438.jpg

Tomorrow I'm hoping to get p&c's and heads installed. I might try to push for cam towers, but could be a stretch. Btw, the ultrasonic cleaner is amazing! Removed all the sludge from the cam towers, chain Boxes, and tin. I shot some solvent through the squirters and blew everything out with air and it looks great so far!

Made a tool for chasing head stud threads. Cost less than $1 and took five minutes to make. Got all the head studs installed. Supertech says length doesn't matter (heh, heh) and they should screw in all the way with little interference, then back out 1/4 turn using blue loctite. They did and ended up consistently 5 7/16" in length.

http://forums.pelicanparts.com/uploa...1443979362.jpg

http://forums.pelicanparts.com/uploa...1443979387.jpg

Also, mocked up my EBS bored (98mm) and plated cylinders and large port twin plug heads. All looks good so far! Installation will start after lunch.

http://forums.pelicanparts.com/uploa...1443979497.jpg

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Any thoughts on torquing heads first, then cam tower or finger tight heads, torque cam towers, then torque heads to spec? I've heard pros/cons on both?

Farging, bastage, wire locks from hades!

My god, those piston pin locks are evil!

Made an exciting job a real pain in the arse. I have cuts, blistered finger, and a foul mood, but I also have p&c's and heads installed. Took me the entire day. I figured once deck height was checked, I'd be good, but no. Anyway, time for alcohol and I'll install the cam towers next weekend and figure out how to time the cams. Should be fun!

http://forums.pelicanparts.com/uploa...1444001754.jpg

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Great work, looks fantastic!

How the heck do you change rods without splitting the case?

Carefully. It's easy to remove the nuts and the rods. To install new pauter rods that use a bolt, slip the cap into place and slightly rotate the crank. Insert one bolt in the rod and while you hold the rod in place, turn the bolt until it catches the cap. Then insert the other bolt and torque to spec. Easy.

Got the cams installed and timed. Installing the rest of the rockers now and adjusting the valves. Should be buttoned up today. BTW, overlap on a DC80 104 is 5.6. I critical piece of information if you want to do it right! Here are some pics:

http://forums.pelicanparts.com/uploa...1444680202.jpg

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Kafer dial indicator.
They make some nice stuff.
Nice to see it come together. Still going to try to get a ride in that rig....

Installed the rest of the rockers, adjusted the valves and bolted on some fancy valve covers. Hmm, not sure I like the fancy valve covers. We'll see as the rest of the engine comes together.

http://forums.pelicanparts.com/uploa...1444693870.jpg

http://forums.pelicanparts.com/uploa...1444693889.jpg

There have been extensive discussions on this in the Rennlist 993 forum, and it strikes me me (a non - wrencher) as quite a complex procedure.

Actually, once you figure it out and have the right tools, it makes perfect sense and is easy just a little time consuming.

I finished buttoning up the engine, gapped and installed the spark plugs (after doing this on a 911 I'd forgotten how easy it is when you have access), and stuck the distributor in (only open holes now are intake, exhaust, and oil in/out).

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I was installing the 3B plug and ran into this:

http://forums.pelicanparts.com/uploa...1444770673.jpg

Interesting that it was cast closed. Anyway, 5 minutes with a sharp hacksaw and I was good to go:


http://forums.pelicanparts.com/uploa...1444770734.jpg

Ya know, if you put this on the hood it'd look kinda like a Smokey and the bandit car.
On second thought, dumb idea. Never mind. :D



http://forums.pelicanparts.com/uploa...1444772880.jpg



BTW love the car, awesome taste.

A screaming chicken. I like how you think!

Started working on the shroud.

http://forums.pelicanparts.com/uploa...1445720028.jpg

Nice Mark! In the next couple of weeks i will drive mine out finally. Let me know if you need a hand


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Great build.
Thanks for letting us in on the goodness (and the frustration from time to time.
Best
Les