Engine rebuild is done...after only 4 wks!
 

Two broken studs started this project. I found them 5 days before I was to head to China for 3 wks. So the night before I left, we had a stealth engine drop (they usually turn into large events around here) and then Charlie had her completely torn down two days later. Some engine porn to follow.

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Why not clean the tranny up a bit too?

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Freshly painted shroud certainly adds a few HP.

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Bird's nest induction.

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An, finally the gratuitous stuff.

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more coming....

P&C's were in good shape.

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And now for the real porn.

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It's a shame these have to go back in the car. I needed all new valves - ouch. ASG is one of the two local shops I trust for anything around here and they were very fast. I think the missing air dam on my alternator may have had something to do with my valves all being worn. Many years of TX and FL driving aren't kind to heads without proper cooling.

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No more leaky return tubes!

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Why not make this a Super Carrera with Carrera tensioners?

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more coming...

More bling. SSI's were very necessary.

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When I came back from China and walked into my garage, Charlie was timing the cams - 964 cams, that is. A few nights later this is where we were.

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Oh yeah, I decided I needed a B&B dual in/out too.

Twas the night before reinstall, and all through the house, not a creature was stirring, because we were drinking beer in the garage.

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more coming...

So Sat. we had a stealth reinstall. MackPipes, SteveV, Jim Richards and Charlie came by for the LONGEST reinstall in NoVA history. Tons of donuts, coffee, beer and pizza later, we were on our way.

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And drumroll please....

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Car fired right up (after we corrected the starter wiring error and built up oil pressure). 20 min. of idling at 2k rpms was an eternity in my cramped condo community. Car is LOUD now. Like I'm very afraid of getting pulled over for this. It's just obnoxious, but then it's also mechanical music. I'm two oil changes into the break-in now and will readjust valves probably next weekend. Oh yeah!

RL, you didn't mention how well it runs now!

Bring Charlie to my house !!!!

Oh yes, it runs like a top. I mean it's scary fast and loud. I have never been more pleased with someone's work. Charlie, quit school and become a house-call mechanic. I hate having my car in someone's shop. It was nice to see the engine every time I walked into my garage and be able to wrench a little on it too.

Looks very nice! Great group of people to help you have there!

Tell us more about it when you get it broken in!

JoeA

It definately pays to live near Va. when it is time to drop an engine...
Good work!

Very nice man, Great job!!

Can I drive my SC down the turnpike to you guys? Or can I borrow Charlie?

Just curious, was this considered a DIY or was Charlie a hired gun? Care to share rough costs?

Adam

Charlie was a hired gun for this one, though he and I have burned up a lot of brain cells with brake cleaner, wrenching together over the last 3 yrs. I haven't totalled receipts yet, but with SSI's, 964 cams, all new valves, headwork, new injectors and a bunch of little stuff, I think it's gonna be around $4500-$5000.

Great, good to know Rick. Thanks.
Adam

Great nwes RL, I am sure it will run well at Summit. good place to break it in too.

When is the 993 coming home to displace the red one in the garage?

993 is coming home within 2 wks and will look better than new. I have garage space lined up for the red one too, so they don't see each other, get jealous and start acting up on me.

Did you have KS alusil cylinders? If so, did you do anything to them? Did you re-ring the pistons? How did you get the carbon off of the piston tops - yours look perfectly clean. I am jealous with your quick turn around - I have been waiting longer than your job took just to get my rocker arms back from Comp. Engineering. My car only had 63k miles and my rebuild also started due to broken studs. We re-used my KS pistons and cylinders without re-ringing as they were in spec. I'm also going with 964 cams in my 81.

Yes, Charlie reringed the Alusil pistons. Some say never, some say it's no problem. No way was I throwing more search time and money into a set of Mahles. Saving the pistons afforded me the SSI's. So far no smoking, but we'll see.

Congrats! Hats off to Charlie...

I agree the cost of new P & C's is absurd. If mine had more miles I might have bumped it to 3.2 w/98mm P & C's, but I had no interest in spending the bucks for the same size Mahle P & C's when my KS seem fine. I hope they will have no problems and last. Good luck with yours. Let us know how it goes as there are many folks out there with KS cylinders that will be having rebuilds, and if re-ringings are successful this will save folks a lot of money. I have heard of several that appear to be success stories, though only time will tell.

Nice work!!
Are you ready to open a express engine rebuild shop?:)