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My old man is a machinist so I decided to ask him for help making some of those fancy cylinder holder nuts for when I put it back together.



Bought some slightly used 9.5:1 JE pistons for a slight compression bump.



I guess I better start tackling this pile of greasy parts.





I dont know why but I find cleaning parts strangely therapeutic.
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Jose - 1983 911SC Coupe

Last edited by 2jmotorsports; 07-12-2016 at 11:29 PM..
Old 07-12-2016, 11:23 PM
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I guess I better start tackling this pile of greasy parts.





I dont know why but I find cleaning parts strangely therapeutic.[/QUOTE]

Very much so .....until you go back and clean them some more and some more.
Then you start to go insane.
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Old 07-13-2016, 06:15 AM
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911 Rod I agree. One of the hard oil lines was particularly maddening to clean.

I just need these clean enough to drop the whole pile off at a powdercoater for blasting and recoating.
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Old 07-13-2016, 07:23 AM
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Congrats on great progress and a great thread!

I am at a similar point with my 1980 911SC, with 190K Kilometers (Euro spec), but I have 10, yes 10, broken lower studs but car was running well when I dropped the engine. I'll start a new thread soon so we can compare notes.

Just wondering (maybe I missed it), did your cylinder head surfaces need to be reconditioned (fly-cut)? If so, where did you get it done?

All the best,
Tom
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Old 07-13-2016, 05:53 PM
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Great job!

Where did you source your drive-up ramps?
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Old 07-13-2016, 06:16 PM
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Ed, I believe I bought those at AutoZone many moons ago. Lightweight plastic ones.
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Old 07-14-2016, 07:07 AM
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Hello again. Progress has been slow, but there has been progress.

Sent my case, crank and rods to be checked and reconditioned. Went with Engine Machine Services as recommended by a friend and about 30 miles away.

Case was cleaned, checked, new oil squirters, and oil galleries were drilled and tapped to be able to clean everything out.




Rods were magged, resized, and rebushed.



Crank was checked, magged, polished, and oil gallery plugs drilled and tapped. Per the advice of the experts I decided to replace my gears as well.



Bought some measuring tools I would soon need. Not high dollar units but I did send them out to get calibrated to be sure they were accurate.


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Old 04-03-2017, 08:50 PM
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Cleaned more parts:



Collected more tools and parts for the bottom end rebuild. Went with ARP rod bolts and GT3 rod bearings.



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Old 04-03-2017, 09:01 PM
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I could not find a tool to hold the crank horizontally and hang the rods, so I made my own using a junk engine adapter.





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Old 04-03-2017, 09:03 PM
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Measured all the crank journals, cleaned the oil gallery out, then screwed in the threaded plugs.




Using Wayne's book, the Bentley, Bruce's book, and the ARP catalog as references, I checked the rod bores, arranged the rods according to their weights, crushed some plastigauge with the ARP bolts stretched to spec and came out ok.











Reassembled a final time with assembly lube and passed the rod drop test with flying colors.





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Last edited by 2jmotorsports; 07-02-2017 at 03:02 PM..
Old 04-03-2017, 09:24 PM
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Old 04-03-2017, 09:26 PM
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Old 04-03-2017, 10:38 PM
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Well done. Your attention to detail bodes well for rebuilding engines.
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Old 04-04-2017, 06:48 AM
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Thanks for the feedback. My target is to do it right the first time so I dont have to open this engine back up for a long long time.
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Old 04-04-2017, 07:41 AM
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Great idea on the crank holder. Where were you last year when I did mine.


Sent from my iPhone using Tapatalk
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Old 04-04-2017, 04:01 PM
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Jose, this is deja vu, for me too. Mine is an 82 black coupe that had 183K and broken studs. The car had had excellent maintenance so was clean inside the case like yours. I'd fretted about splitting the case until my local expert told me to man up and strap on a pair...the mains were fine, the rods a bit worn and the intermediate shaft bearings were showing bronze. I also had Alusils and was freaking out about that until Tom at Tom's Rennshop suggested I let him look at them. He cleaned both the pistons and cylinders, found everything to measure in spec, then honed the jugs with special slurry/paste and reassembled with the original rings. The motor proved to be strong and runs fantastic, and not having to do a Nikasil or new JE upgrade saved my budget bacon. I found Wayne's engine book to be a truly excellent resource. Great job. It's an amazing feeling when the motor first starts once you get it all back together and in the car. Keep on nibbling away at it. John in CT
Old 04-04-2017, 04:58 PM
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Thanks John. I may reconsider reusing my KS cylinders once I have my case sealed. Which hopefully is very soon.

I next turned my attention to the intermediate shaft. Damn that snaggletoothed gear.



Snap rings off.



Found this set of arbor plates at work, right next to the press I planned on using. Fits the chain sprocket perfectly.



Sprocket vs 15 ton press. Who will win?



Press of course.



Exploded the rest of it.

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Old 04-04-2017, 08:43 PM
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Cleaned out the oil gallery and replaced the plug. Reassembled with new gear, lock tabs, sprockets, and snap rings.




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Old 04-04-2017, 08:47 PM
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Wow, good Job Brother Good JOB!
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Old 04-04-2017, 09:28 PM
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Love this thread, at the end of this your going to have a motor that looks like it just rolled out of the factory.

How much rebuilding experience have you had?
Old 04-05-2017, 06:29 AM
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