For the cost of a 3.0 rebuild....consider a 3.6 from Steve Timmins. He's in DE and you get instant reliable 280-300HP. InstantG's Home Page

T77911s,
If you go in the engine rebuilding forum and do a search on the whole Alusil cylinder thing you will find a HUGE thread on it. I believe that there is some information about that there. but it is pages and pages and pages long. I am almost surprised that nobody got shot over that thread!

I guess I know where the oil leak was coming from :mad:.

http://forums.pelicanparts.com/uploa...1271308370.jpg


You can see where the stud is missing. We haven't taken the cylinders off yet but it looks like it snapped close the the case. It's amazing that the remnants are no where to be found!! Which, as I mentioned previously, means someone, some where put everything back together that way. So much for a PPI :rolleyes:.
Anyway, I'm sticking to a stock rebuild for two reasons - One, I don't/didn't use the power the cas has/had. With the SSI's, M&K and a good, solid, tight rebuild I think the car will be just fine for me. And two, money. I don't see where I'd get the payback being that I don't track the car or AX, if anything maybe a DE or two once in a while, but it's a daily driver so reliability is key.
I'm hoping to get the cylinders off tomorrow and from there build a final parts list. I'll be doing all the standard seals, "replace while you have the engine out" things, new timing chains, ramps, etc.... and obviously stock CIS P&C's. Going over the CIS and replacing all rubber as well as cleaning it. Repainting all engine tin, shround. etc... and maybe polishing the fan if time permits. I think when all is said and done, and with the heater backdate, things will look nice a neat back there and hopefully I'll have my car back in a couple three weeks.

Do not use new chains on old chain sprockets (The ones on the I-shaft)

New chains without new sprockets? Read this! - Pelican Parts Technical BBS

Each cam has 3 sprockets: Cam sprocket, chain sprocket and idler sprocket. The chain sprocket on the I-shaft is the driver and wears more than the other 2. A new chain will ride on the tips of the teeth and eventually break them. Dual-chains don't stretch; they wear along with the sprocket-teeth and new chains cannot seat into worn teeth-bottoms.

If you don't use new chain sprockets, re-use the old chains. Post pictures of each side and we'll tell you if the tensioners still have enough room for extension. New ramps is good.

As for P/C's, one cannot be sure about make untill they're off. Alusil shows KS and Nikasil shows Mahle. I've seen Mahle with and without center strip.

If you have Alusil, it's up to you if you want to re-ring etc. and take a chance. The condition and spec of the first land will tell the story.

I hope you have Wayne's book on Engine Rebuild.

Thanks Gunter. New sprockets were on the list, and yes, both of Waynes books and the Bently are within arms reach.

Once you decide to split the case then you get to read up on how to seal the case halves. I believe there are tons of threads on that subject too! The fun never ends.

To be clear: The chain sprockets I am talking about are on the Intermediate shaft.
The case has to be split to exchange them.

Experience has shown that they wear more than the others because they are the "drivers".
The cam sprockets and the idler wear much less and I have re-used them successfully.

So, new chains and new chain sprockets on the I-shaft, new ramps, re-use old cam sprockets and idler.

If you don't want to split the case, re-use the old chain and sprockets and just install new ramps. Post pix of the tensioners before dismantling.

I re-ringed my Alusils at 183K miles, and they never smoked. Not even a tiny bit. There is a "Re-Ringing Alusils" on the Engine Rebuild Form. WAY more than you want to know about Alusil and Nikasil technology.

The most wear I could find on my cylinders was .0015". Miniscule. I believe the trick is to clean them up VERY good, and oil them VERY lightly.

Too late chain tensioners are already dismanteled. I get what you're saying about the driver sprocket and I have no intention of splitting the case. There's no reason to believe it has to be for now. I'll mention the reusing of timing chains and sprockets (with new ramps) to my buddy.
I have a set of recond p&c's coming from Tom Butler and this time around wrt rebuilding, I'm only looking to sort things out that are needed and not go crazy. If it turns out I need to do it again down the road then I'll either buy a completely new rebuilt engine or rebuild mine with upgrades. Right now I have a limited budget and limited time, meaning I don't have months and months to collect parts and do things as money and time allow. I have to sell some of my other toys and build up a good nest egg for stuff down the road.
Anyone wanna buy a replica 58 carrera or a 125cc road racing go kart? ;)

With more than 30 years of ME experience, I can tell you that in Industrial applications new chains are always matched with new sprockets during regular maintenance.
Only on rare occasions like a break-down was a new chain installed to keep production going but later a new sprocket was added.

Very few bikers would install a new chain and not change the sprocket.

A simple test will show you: Wrap a new chain around a well-used sprocket and you'll see that it doesn't fully seat.

I trust the durability of the dual-chain used by Porsche and would not hesitate to leave it in place if the case is not split. In short, I'd re-use all sprockets and only get new ramps.
Getting new idler- and cam sprockets and a new chain without changing the bottom chain sprockets is an unnecessary expense and will do nothing for performance.

People do feed new chains onto old I-shaft sprockets but if they could see how badly it fits they might think twice. :)

Post a picture of the 58 replica. Is it an Intermeccanica?

Here ya go Gunter! Yes, it's an older IM. Made by Frank Reisner (his son Henry makes them in Canada now).


http://forums.pelicanparts.com/uploa...1271435278.jpg

Man, that looks nice.

Disc brakes?
1.6 liter?
4-speed?

When you're ready to sell, more details and more pictures appreciated:

aquastar@netidea.com

Making some progress. Got the heads back today (new springs, seats, guides, regrind, etc...) The new lower studs went in and we cleaned up the case. Unfortunately I had to leave for a meeting so I could stick around for more reassembly. Not sure how far they got after I left, I'll find out tomorrow.

http://forums.pelicanparts.com/uploa...1272500534.jpg

http://forums.pelicanparts.com/uploa...1272500553.jpg

Its been years since I ve see dilivars go back in..
Bruce, previously from Middletown, De

Bruce, Theyre not Dilivars, theyre steel.

Mickey, Looking good. who is doing the machining for you. There are a couple guys up there very capable. Just wondering who you went with. I ask because I will be looking to do the same thing this winter.

Mickey - how bad is the corrosion on the two lower-right studs? If more than light surface rust I would replace them also, easy to do now...

Sailchef,
I had Alderman do the machine work on the heads. I'd seen alot of their work going through my buddies shop and it was always top notch.


GaryR,
I gave the top studs a good look over and those two are the worst (it's only very light surface rust). I thought about replacing all of them but after reading posts and Waynes book about if it ain't broke...... and the near non-existent occasions of steel studs breaking, I figured I'd leave well enough alone.

Heads went on this morning and when I left he was starting in on the new chains and chain ramps. I know Gunter is against new chians without new sprockets but in Waynes book he says a new masterlink chain is better than an old worn chain so I went ahead with it, I guess we'll see.

I guess like many folks here I'm at the early learning stages and struggling with alot of decisions. It seems that you can always get two sides to something (reusing Alusils, splitting the case or not, new chains or reuse the old ones, etc...) so you reach a point where you just have to make a decision and go with it. Of course I hope I'm making al the right ones but it remains to be seen until we get it all together and back on the road. I'm keeping my fingers crossed. ;)

http://forums.pelicanparts.com/uploa...1272554543.jpg

Gettin there.............

http://forums.pelicanparts.com/uploa...1273164194.jpg


http://forums.pelicanparts.com/uploa...1273164218.jpg


And of course every DIY'ers friend (torque wrench and Waynes book)
http://forums.pelicanparts.com/uploa...1273164267.jpg