Bump for an update?

7 weeks, no progress. Shop is busy I guess.

There is an oil leak that they wanted to address before trying to start it, but that was discussed when it got delivered.

I've resigned myself to the fact it won't be driven this year and instead played some golf and tried not to think about having a six figure paper weight.

It's a six figure appreciating asset! Bummer about the wait.

New hear and just hit the subscribe button. Wow what a story...... It will get there.....

Quick update.

Car is still at the shop. They had found a fuel leak from the AN fitting that I had welded (poorly) onto the tank.

Since I chewed through another starter ring, they dropped the motor and transmission and went about double checking the cam timing.

Rebuild Newbie f*ckup #1 - cam timing is supposed to be 4.2-4.45mm. Bank 1 is currently set at 7.53mm and bank 2 is set at 4.49mm. This is obviously an issue!!

Rebuild Newbie f*ckup #2 - Cylinder leakdown shows cylinder 1 with 100% leakage. This is slightly out of spec...The good news (I think it's good news?) is that the leak is coming between the cylinder and the head.

The shop is going to tear down bank #1 and see what I did wrong.

The adventures of being an amateur engine builder and car restorer continue. At least this better explains why the engine wouldn't run, even after I got the firing order corrected.

Also, than heaven for deep valve relief pockets with the cam timing being that far out.

Will know more once they tear down bank 1, but so far looks like the only thing hurt is my pride and wallet.

That is more good than bad news.
It also affirms that you made the right call taking it to a pro.

Sometimes, it's a better bet to punt than go for it.

So the starter ring got chewed up because the improper cam timing caused the valves to jam the pistons and stop the engine from turning over? You comment on the deep valve pockets would lead me to believe that's not the case, so what caused the starter ring issues (if you know yet?).

Bill

Engine never jammed up. Seems to be an alignment issue between the high torque IMI starter and the starter ring.

Engine spins freely, but I believe backfire from poor cam timing bends a tooth then the shredding cycle begins.

So refreshing to hear an absolutely honest reflection on a challenging rebuild like this. Thank you. Rebuilding a Porsche motor is a demanding project. Good on you for taking a swing and thank you for your honesty!!

Thanks.

I really THOUGHT I had done it right. One error looking back on things was trying to set timing with the Rothsport pulley. I think that's one area where I went wrong. The other point on the cam timing I would say is that I didn't buy a Z block, but rather used a magnetic base. I think there is a good chance that this corner that I cut lead to the incorrect cam timing.

The cylinder head leak, I'm not too sure on, but will be interesting to hear the prognosis. Given that the leak is between the head and the cylinder, I think it is safe to assume that we aren't looking at a damaged head, but rather an installation error of some kind.

Possibly a missing cylinder base gasket on that cylinder, the other two have them installed so one cylinder isn't sealing to the head properly? That's easy to check for at least.

leakdown was between 2-5% on all other cylinders. 100% leakdown on cylinder 1. No cylinder head gasket on the 98mm Mahle barrels. Maybe a foreign object?

I'm obviously not an expert, but could be the cylinder is sitting too low preventing the head from clamping? Either way, its in the very capable hands of a local shop that is fitting it in amongst there many other customers.

Really happy to hear they are getting somewhere with it! Fingers crossed it's something simple. Maybe they left out the bottom spark plug when they were doing the leakdown on #1?

Not too sure! I'm pretty sure the guy that did my heads does it for them as well.

Well best of luck regardless. One thing I'm sure of, whatever lies ahead, is that it's going to be worth it in the end!!!

Almost sounds like it was submerged in a flood.

turns out the leak on cylinder 1 was the lower sparkplug not sealing properly.

That's great news! So, it'll be running and back to you soon?

Best case scenario right there !

Here's hoping I'll have it back pretty soon! Still lots of work left to do, but fingers crossed I'll at least be able to take it out for a shakedown run on the 4 year anniversary of its purchase.

The big unknown still is the condition of the transmission.

For anyone rebuilding their own engine, don't cheap out and skip the Z block. I used a magnetic base and I think that contributed to me screwing up the cam timing.

Luck be a lady!
This is fantastic news.

Yup, for whatever reason, the lower plug hole on that one cylinder always felt tight threading in, like it was cross threading.

I've been really happy with the communication and checking in on different stages before just rushing ahead and doing work. They had found some issues with the hardware used to assemble the engine and some of the application of sealant, but I'm going to roll the dice on there being any leaks.

Fingers crossed it will be in the garage just after Christmas.

Great to hear there are no (very) expensive problem to fix, such as a bent rod from the engine hydrolocking, or the pistons hitting the valves.

http://forums.pelicanparts.com/suppo...s/beerchug.gif



Given that many of us (including myself) are starting from the exact same starting point as you


It would be super helpful to find out what went wrong with your DIY engine rebuild.


Triple checking the cam timing using a Z-block is already highlighted on my list! ;)

Lukas, I would say that I made 2 mistakes on the engine rebuild.

#1 - Being cheap and impatient and not buying a Z block. Lockdowns kept the border closed and I should have just bit the bullet and bought one instead of using a magnetic block.

#2 - If I were to do it over again, I would use a degree wheel to find true TDC instead of relying on timing marks on a pulley.

Mistake #1 is what caused the right hand bank to be out by a ton. Mistake #2 contributed to bank #2 being out by a small amount.


I really didn't expect cam timing to be my issue because it wasn't a problem when I redid the top end on a CBR600RR that included installing a milled head and degreeing the cams to HRC supersport spec.

To put the Honda cam timing into perspective, the piston to head clearance required shallower spark plugs to clear the pistons and the Piston to Valve clearance was almost non-existent. That's on a shim under bucket arrangement as well, which is extra super fun.

But I digress, amateur builders out there, try not to make the amateurish mistakes that I made. Buy the right tools, don't cut corners.

Very helpful advice, many thanks for sharing it with us instead of sweeping it under the rug!

I already have more than one 911 project car that I bought cheap(ish) and am now paying the price later, so will invest in the right tools as I don't have the money to get them rebuilt professionally and/or blow them up. ��

Fingers crossed that Jeff is able to sort yours out and the ring gear issue is then solved for good. Even if that part is not that expensive, major PITA to to get to it.

Just got off the phone with the shop and my car is now running and idling pretty well.

There is an oil leak that I need to take care of which is coming from one of my oil hardlines. I had removed and resoldered the Akron fitting (i think that's what they are called) but the sonof***** is leaking.

My buddy is an HVAC repair and should be able to repair it, I had reused the old fitting with a new nut.

I'm in my busiest time of the year at work, but I will have the car towed home and be able to tinker here and there to get it road worthy for the summer.

Thanks for all the support from the Pelican Community.

Excellent news!

Will you (and the car) be at Rennsport this fall?

I think that might be a 2024 target. I've never been, is it always in Monterey?

I used to go to Laguna for the MotoGP races. Would be fun to check it out.

Small Update - One step forward, one step back.

I got the car back smack in the middle of my busiest time of the year at work, so it basically sat for another 4 months.

So it's basically been a year since I made any meaningful progress on the car.

I was able to get the oil leak fixed as my buddy from motorcycle racing days sliver soldered on new steel nipples to the hard oil lines and the leak is gone. YAY!

I climbed in and noticed that the clutch pedal was on the floor, that's when I noticed that the clutch cable clevis pin wasn't inserted all the way and the clevis bent. Not sure if this was me or the shop that worked on it, but now I have another delay in moving the car under it's own power.

I really wanted to move the car and have it facing forward in the garage as the tow truck dropped it off butt first. I guess that will have to wait for next weekend when the parts come in.

I did fire up the motor and oh my. It sounds glorious.

Hope to have some meaningful updates through the rest of the summer.

Glad to see an update. I thoroughly enjoy your build thread and glad to hear you may be getting back on it. Random pics always appreciated, lol.
Reading back thru this thread. Forgot how pretty the work is that went into it. Post 98 for instance... so nice.

http://forums.pelicanparts.com/uploa...1689020436.jpg

Big milestone over the weekend as Mickey Mouse moved under its own power for the first time in almost 20 years.

Still tons to do, but after replacing the clutch clevis and pin, I was able to start it up, pull it out onto the street, and pull back into the driveway.

Gave the car a quick bath and now more motivated than ever to make progress on this thing.

At least I know for sure that 1st gear and reverse work!

More updates as time permits. Both kids are playing summer league baseball, but I want to start crossing items off the list to be able to get it out for some break-in miles.

Excellent!
No matter how brief, that first drive is always a big milestone.

Good to hear. Keep driving it regularly, even if a little bit. Mine was a "20 year" project that lost momentum and I kept pushing it back in the garage because I had other more pressing things to do. The longer it sat, the more things it needed, and the more time I lost. Now that you have regained momentum, don't lose it.

Thanks guys.

I'm trying to break it down into bite sized pieces and get the car into a state that I can drive it from Point A to Point A.

As I mentioned in Chris' thread, I had the door frames powder coated and it looks like they over heated them and they need better fitting. I made the executive decision to go with doors and no window frames for now.

Next mini-project will be to get the parking brake setup properly. The cable into the backing plate seems to pop out then the parking brake doesn't work. All the parts are new, just the setup is off.

Would love to have an update, big fan of this build!

I've made a bit of progress, but I've decided that if I can't get it road worthy by February then I'll send it to a shop to wrap up to a drivable state or I'll miss another summer.

Owning your own business and having very active kids is a real challenge.

Great thread. Can't believe I just stumbled across it. As I'm stuck at home getting over Covid, the thread helped pass the time today.

I recently spent the last year or so rebuilding my 914-6 and getting it back on the road. For every step forward it seems there is always one or two things that always set you back. It's part of the game I suppose, but there's nothing more fulfilling than finally getting your car on the road.

Cuss words were said.

Tools were thrown.

Finally, phone calls were made.

I knew I would need some shop help as I pulled the spring plate bosses when I was installing the Rebel Racing spring plate bushings. I also noticed after the car was painted that 2 of the 3 oil line brackets were no longer attached.

I have an all new appreciation for guys like Jonny, Jim and the others who can assemble these cars because even with all new parts from Porsche, this little bugger did not want to cooperate.

So back on the flat deck she went and over to a Porsche enthusiast that has started his own shop after years of buying/selling and restoring 911s. We both used the same painter and have chatted a bunch through Instagram.

We found some flaws in my work, and some parts that despite being new, just don't fit very well. We'll get there, should still be able to drive the car this year as we are nearing the completion (or at least the 95% mark) of the project.

The exhaust system is not the final iteration, and there may be some additional changes, but it's getting there.

http://forums.pelicanparts.com/uploa...1725821364.jpg
http://forums.pelicanparts.com/uploa...1725821364.jpg
http://forums.pelicanparts.com/uploa...1725821364.jpg

You are so close!!! It must be inspiring to be able to fire it up and move it under its own power, at least.

The last 5% is the hardest, move frustrating, and time intensive. Compounded by the fact that nothing ever seems to go the way it should - you'd often swear (literally and out loud!) that the parts were made for a different car!

My #1 advice to anyone restoring one of these cars is not to be tempted to buy too many parts before you're in a position to use them. You pull a seal (the worst offenders) out of the package from 2 or 3 years ago you have little recourse to return it. At least if you got it 2 weeks ago you can send it back and try from another source.