Waynes Rebuild Book

[khamul02]

Just finished reading my Chirstmas/Festivus gift. Great read. I'm not sure I'm ready to tackle a rebuild. I'm not due, thank god. But this book gives me (I think) a great understanding of what's involved and needed for a rebuild.

Bottom line. Highly recommended read, even if you aren't going to rebuild at least you'll know what your wrench is talking to you about during the process.

[LakeCleElum]

Tom: I'm with you. Don't need to do a rebuild yet, but will do someday. 3-5 years probably. Buying and reading the book was a step in preparation. Great job Wayne!!!!!!!!

[ZOA NOM]

Just do it!

[khamul02]

ZOANAS, what was your mech skill level when you did yours? I never changed oil in a car before my SC. Now I've adjusted the valves and done a number of other mildly complex jobs. Mind you, my bs is in I.E. so I have some tech skill just not automotive. It just seems like every task has some little trick if there's trouble. Best left the to guys in the know. I know at knowledge level right now I'll at the least drop the engine and do a complete dissasembly. But I'll proably leave the rest to the pros.

[75Carrera]

"It just seems like every task has some little trick if there's trouble"

You can say that again...

Porsche must be a German word meaning "optional or ocassional precision"
I've yet to do very many projects that came apart or went back together without knowing one trick or another.

But, there is great satisfaction in learning some of those tricks!

[ZOA NOM]

Originally posted by khamul02
ZOANAS, what was your mech skill level when you did yours? I never changed oil in a car before my SC. Now I've adjusted the valves and done a number of other mildly complex jobs. Mind you, my bs is in I.E. so I have some tech skill just not automotive. It just seems like every task has some little trick if there's trouble. Best left the to guys in the know. I know at knowledge level right now I'll at the least drop the engine and do a complete dissasembly. But I'll proably leave the rest to the pros.

Very mechanically inclined, but inexperienced. This is my first engine rebuild, and I will let the pros handle the details. I'll do the assembly, however. I'm enjoying the experience, and I've just let go of the fear. I figure I'll either get it right, or I'll have a pretty expensive paper weight when I'm done. Either way, I'll be much more knowledgeable about these cars when it's over. With this forum, and guys I've met through tracking the car, I don't worry too much.


I have to say the disassembly was rather easy. I used Wayne's rebuild book, and took my time. The worst part was trying to remove my Alusil P&C's as a unit so I could re-use them. In the end, I found a nice set of Nikasil's, so it was all for naught. Now I'm ready to send out parts to the machinists.

[Grady Clay]

I think there should be a thread (or Forum) complimenting and extending the book. There are many simple items not covered and there are also many subjects that need extending.

The fun part of a 911 engine is it is easy – it just has a lot of parts. The remarkable engineering Porsche put into it insured that. Historically Porsche has had primer replacement parts. Today, the issue is diagnosis, measurement and the choice of (parts & services) suppliers.

We don’t want to preclude Wayne from a “2nd Edition” but there is a lot already posted on 911Technical and 911 Engine.

The problem with publishing a book is you are limited with pages, format, etc. On-line there is no limit. I hope Wayne can make money with the on-line resource he provides AND a “2nd Edition.” I would pay Ludvigsen price for a more complete edition – and contribute for free.

One of these days there is going to be a comprehensive, multi-volume publication of “The Complete 911 Engine” that includes all the 6-cylinders (745, 821, 906-> 997 and more).

A chapter I would like to see is what we could whisper to the engineers in ’60- ’62, given our experience. HeHe.

Best,
Grady

[khamul02]

Great to know. Good luck with the rebuild!!

[Grady Clay]

ZOANAS,

Do you have another thread going on your progress? If not, start one on the 911 Engine Forum. Be sure to include all links like this: How do the camshaft cover plates come off?


Some of the best threads are start-to-finish projects like yours. Please do others a favor and post every little frustrating detail.

I’ll be glad to help.

Best,
Grady

[ZOA NOM]

OK, I'll do the best I can. The teardown was pretty straightforward, and Wayne's book does a great job of including pics for everything. I'll be sure to post a thread when I start the assembly. Be patient, I don't have to have the motor running until the first race in March, so I'm sure it'll ramp up as the time nears.

[Grady Clay]

ZOANAS,

Great!

You will find times like:
The crankshaft and rods are back. You are ready to assemble the rods on the crank. What do you need to check?

Dempsey 911 Engines pages 114-124 are some of the most important. BA chapter 4 is also very useful. So are the FWM and Bentley.

I think it prudent to have access to all this info.

Best,
Grady

[ZOA NOM]

Great advice, Grady. It's not nearly as intimidating once you leap off the cliff!. The Toyo Spec series requires a stock motor, so I don't have to worry too much about performance mods, etc. I have the latitude to strengthen the weaknesses like rod bolts and head studs, but that's about it. If all goes well with this one, I may swap it with my daily driver while I rebuild that one!

[the]

It's a great book. I don't have a 911 engine needing rebuilding, and don't plan on doing a rebuild any time soon, but I still bought the book and enjoyed reading it - cover to cover like a novel!

[vash]

damn, rick...you got far!

[ZOA NOM]

Glad to see you made it back from Denver, Cliffy! The car is trailered up ready for the trip to Milpitas in the morning. Full cage time!

[LeeH]

I'm finding that the more I read the easier the task is. I bet I read 3 hours worth of tricks and trials concerning the flywheel seal. Actual time installing? About 5 minutes.

If it weren't for Wayne's book I'd have just had the car towed to the shop.

ZOANAS... I'd be very interested in hearing about your experience removing the cylinders. I'm considering doing the same. What was that like and how long did it take you?

[Wayne 962]

Thanks for the kudos guys. I wrote the book to contain 100% of the information that you would need to rebuild, and the book basically fills that task. If you have questions, or need additional info, there is tons of in the Engine Rebuild Forum, which was started when the book was published, in order to fill the gaps and answer questions that weren't 100% clear in the book...

-Wayne

[ZOA NOM]

Originally posted by LeeH
I'm finding that the more I read the easier the task is. I bet I read 3 hours worth of tricks and trials concerning the flywheel seal. Actual time installing? About 5 minutes.

If it weren't for Wayne's book I'd have just had the car towed to the shop.

ZOANAS... I'd be very interested in hearing about your experience removing the cylinders. I'm considering doing the same. What was that like and how long did it take you?

It really wasn't bad. The worst part was finding a workable attachment for my slide hammer to tap out the wrist pins with. Also, I found it easiest to remove the outboard P&C's first, and do the middle one last. It seemed to work best for access to the wrist pins. The cylinder will ride up far enough on the piston to clear the wrist pin, with only a few mm before the rings start to show. I had to keep a positive grip on the assembly while tapping out the wrist pins so the piston wouldn't wiggle out the bottom.

[livi]

Does it come in a Swedish translation?

I´ll buy it anyway. Love to read and learn (theoretically) about our cars. Problem is there are too many technical terms that I have problems translating. Even with a dictionary.

[hcoles]

Markus,
if you ask re. technical terms I will try to answer if I see the question...am sure others will help also. I used the Wayne book and did a complete top end DIY. use PM henry.coles@hp.com if you like...
I'm not an expert like many on this forum but with MSME and many years of DIY I understand most things or can point you in a direction or say I don't know.
-Henry