Finally decided on Engine rebuild vs. replace
 

After much help from this board (responses to my post and reading all the recent engine rebuild posts!) I've decided to rebuild my 2.2 following Warren's suggestion.

Compression and Leak Down numbers

The entire engine is completely torn down and showed really bad valve stem wear and worn out pistons.

I first started going the 3.0 engine to 3.2 upgrade and found myself in a very expensive rat hole. I did consider the 3.6 but really didn't want to go that route due to having to upgrade everything else (brakes, tires, suspension, etc.). I really want a nice weekend cruiser that won't see any track time.

So, I contacted EBS and purchased the JE 85mm pistons, had them bore my cylinders, resurface and rebuild the heads with new valves and teflon stem seals (are teflon seals the way to go here??) and reground the cams to an E grind. Don at EBS was very nice to work with and they were very helpful and quick to turnaround the parts.

I have a local shop (finally found a good shop!) working on the rebuild currently...couldn't wait for Waynes book :(

I hope to have the engine back together in the next couple weeks!! I also have a new duck tail and 72 S spoiler waiting to be added. I can't wait to finally get this thing back on the road again!!

I've also spent a great deal of time painting the engine compartment, fender wells, and having all the engine tin powder coated as well as blasting the fan and spraying with clear coat (soon). I've attached a few pics and will add more when she's all back together again.

My wallet is a few pounds lighter..and still losing weight :)

http://forums.pelicanparts.com/uploads/pistons.jpg http://forums.pelicanparts.com/uploads/all parts3.jpg
http://forums.pelicanparts.com/uploads/spoiler.jpg http://forums.pelicanparts.com/uploads/ducktail2.jpg
http://forums.pelicanparts.com/uploads/enginecomp2.jpg

--Dan

1970 911T Targa
1997 993 Targa

Hi Dan. The B&W version of my book will be available next week. I suggest that you have us FEDEX you a copy when it's done.

Most local shops don't have a clue as to what they are doing. I haven't dealth with EBS before, and I'm not sure which machine shop they use, but I haven't heard any complaints.

The book details what questions you should ask your mechanic *before* you have your engine rebuild. Particularly in your case, here are some good ones:

- Are you having the oil-bypass modification performed? Good for any engine.

- What about cylinder spigots? Are you having them resurfaced? Your engine case will deform and possibly leak if not.

- What about the case-savers or time-serts. I have photo-proof that time-serts are bad news.

- Did you know that Mahle offers replacement Nikasil pistons and cylinders for the early cars? The JEs are good pistons, but your cylinders will wear out much quicker now.

- What guides do they use? Walt at Competition Engineering uses guides that are specifically sized to the hole in the head. This prevents the head from being deformed when the guides are pressed into it. Very few machine shops perform this - not doing so can lead to valve guide problems later on.

This is only a small subset of questions you need to ask. I don't mean to alarm you, but I certainly want to make sure you get your $8K worth. As we have seen on this board, many, many, other people have spent lots, and lots of $$$ having their engine rebuilt, only to end up with a big pile of junk.

It's not necessarily the rebuilder's fault - if you have only done one or two of these engines, then there are lots, and lots of things that you cannot possibly know. Only people who have rebuilt hundreds (like my technical editors for the book) of these can know...

If you can, I would have them hold off for a week or two, until you are armed with the right information...

-Wayne

Thanks for your repsonse Wayne. I will certainly get the BW copy of your book next week. How much wear would be expected from the JE pistons vs Mahle? I only expect to drive the car 2,500 miles/yr at the most...I hope to get several years from this rebuild.

Thanks,
Dan