Engine Rebuild Cost Data Point

[Jim Sims]

My son and I recently finished a rebuild/restoration/upgrade of his '73 911T engine (w/CIS). The cost was $8700. The goals were a dependable daily driver, doing a good job plus learning and spending time together. We did as much of the labor as possible ourselves but sublet the machine work to German Precision and Elgin Cams.

This was an almost worst case engine rebuild situation: car odomenter indicated 144,000 miles, a piston/head appeared to have self-destructed and been replaced plus the "Dukes of Hazard" must have worked on the engine. The case (spun thrust bearing - it spun in the case!) and P&C's were not reusable, five broken head exhaust studs, timing gears were chipped or worn and all timing chain drive parts were worn out. Amazingly, the engine actually ran okay in this condition but the spun thrust bearing was a ticking time bomb and the engine leaked oil from about 40 places.

Upgrades: upper and lower "turbo" valve covers, pressure fed chain tensioners, chain tensioner idler sprocket support arms, timeserted case layshaft stud, SSI's, valve guides and seals and racing seals on rocker arm shafts. Reconditioned: crank (checked, polished and Speedi-sleev on grooved oil seal land), cams (built up as required and reground to original T specs.), heads (checked and cleaned, new guides and seals, seats reground and valves replaced as required, broken studs removed and holes repaired as required plus new fuel injector seals), connecting rods (rebushed, reamed and remachined) and flywheel faced.

New: P&C's, all journal bearing shells, all seals, sheet metal hardware, both engine wiring harnesses, spark plug wires, plugs, dist. cap., rotor, points, rocker arms, shafts and adjuster screws (the "Dukes" stretched them), chains, chain sprockets, ramps, timing gears, fan, fan pulley half, all heater box, vacuum ,oil and fuel lines and hoses, plus many other fasteners and misc hardware items.

Good used parts installed: case, oil pump, one chain case, A/C brackets and a two groove crank pulley (for future A/C).

We did the engine removal, all initial cleaning (Porsche "Boot Camp"), disassembly, more cleaning (seemed endless!), painting (engine sheet metal and shroud, brackets, intake runners, etc.), and reassembly. We bought a few tools but were able to borrow most of them including all the specialized Porsche engine tools and fixtures. Reassembly was a pleasant and satisfying experience. We had a very experienced and generous mentor. My son is now deep into a glass out body restoration of the car. A suspension and transmission rebuild are also planned for the near future. Cheers.

[jsmarcus]

Get some pictures up here! We love to see the progress!!!

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Josh
Black on Black '84 Carrera

[Jdub]

Yes, let's see the pictures! What a great father-son project. Sure wish my dad had taken an interest in the MGA Coupe we had stored in the garage...

Jw