Cost for parts and machine work 2.7 rebuild
 

How much have you guys spent on a stock-ish 2.7 engine rebuild?

I can do some of the machining myself, I’ve got a Bridgeport and lathe. What I’m estimating is

* align bore case: $400
* rechrome and hone cylinders: $1200
* carrera tensioners: $700
* bearings and gaskets: $400
* JE pistons $700
* polish crank, hone rods: $300
* balance: $200
* timing chains $120
* dilavar studs: $500

I can build the heads myself, easy enough to replace the valve guides.

So I’m estimating about $4500

I’ll also be running Megasquirt with coil on plug ignition, and wideband O2, already got all the injection components.

I’d also like to get the cams reground to 911 E spec.

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Align bore? You may want to check on availabilty and cost of oversize bearings before committing to this. Cases can be brought back to stock, but way more than $400.

If you have Mahle Nicasils you may not need this. Otherwise yes.

Carrera tensioners? Rebuild what you have for way less.

Bearings and gaskets, $400, yea, but you can doulble that with everything else, like chains and misc.

JE pistons are about $1000.

Balance? What are you balancing? A good scale will do the rods and pistons, which is good enough for most.

Studs. Why divilar? The stock steel studs are bullet proof. You will need to install case savers in the case though.

Cams will be $1000 if you want E grinds.

You can do your heads, but unless you have a way to grind the seats and valves, assuming your valves can be reused, you will be better off sending them to someone who has experience doing the job.

Do you have Wayne's and Bruce's books?

This was from end of 2015.

"BOX AND SHIPPING CASE HALFS, SEND TO OLLIE'S TO HAVE INSPECTED, LINE BORE
CASE BACK TO STANDARD, SPOT FACE THRU BOLT HOLES, CLEAN OIL SQUIRTERS, R&R OIL 0.00
PLUGS, HOT TANK. BOX AND SHIP BACK"

$1855.07

Case already had casesavers/timecerts (I forget which one). Case back came std/std.

Shipping was additional.

Only details I got on what was done is above.

An awful lot of the time those cases don't need to be align bored. Only go down that path if you must, and have Ollie's the work. Otherwise, stock steel head studs along with case savers and that block is good to go.

If your Mahle liners need work, I highly suggest you not discount using 92mm iron liners (for 2.8L) with JE pistons. This is a subject of an awful lot of controversy for some reason, but I can tell you that just yesterday and Saturday I was at the Mitty vintage races at Road Atlanta and there were all manner of high bhp air-cooled 911s, 356s, and super high bhp VW bugs running iron liners just fine. Just like any other part, thoroughly check them over first.

A 2.7L rebuild for under $5K? Maybe 20 years ago, but not anymore. Any respectable rebuild of a magnesium-case 911 engine will see $15K very easily. Let's say you do all the labor yourself, that still leaves 50% of that in parts.

I can do a lot of the machining myself, got a full size Bridgeport and lathe, so I can easily tap for case savers.

So in the OP, what items have I missed for parts? Are my price estimates way off?

Basically, if my estimate is way off, then I need to completely rethink this entire project.


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Tensioner upgrade kit> $2K
You need valve job: $1K to $2K depending on how much assembly you do
Pistons and rings ? Where are those?
Bearings and gaskets for $400? Where from?
Then when the engine goes back in, will there be new hoses, new oil lines, broken air box, ignition wires, spark plugs, ignition dizzy and coils, and heater boxes, and heater back date and they absolutely snow ball from there.

$4,500? No way.

Both Bruce Anderson's and Wayne's books have listed all the needs for a rebuild.
Without these books you are going to miss a lot of information. Yes this forum is great but it is not a step by step tutorial.
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I put together a quick spreadsheet of my three options. I don't know, all these options have issues with them. Probably the worst is the risk of catastrophic failure in a 2.7.

http://forums.pelicanparts.com/uploa...1556560840.jpg

I've got most of those book, plus, I've built seven or eight 2.7 and 3.0 engines before for customers when I worked in why uncle's VW/Porsche shop. But since then, parts prices have gone completely insane.

Build the 2.7! If you reach your budget cap and you arent done yet, you can shelve it and proceed slowly as the budget allows.

Took me 3.5 years to finish a 3.0L rebuild which I didnt have a ton of spare time to work on anyway. An hour and a few dollars at a time steadily until its done. :cool: