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Quote:
Originally Posted by Eli W View Post
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?
This is my first rebuild ever. This is why its moving so slowly.
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Jose - 1983 911SC Coupe
Old 04-05-2017, 07:55 AM
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Awesome!

That gives me hope, I have never done one, but it looks like you are doing a great job. I have never done one before either but would not mind the challenge.
Old 04-05-2017, 08:18 AM
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This thread is great!
Old 04-06-2017, 04:09 PM
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After many many checks, re-checks, and a bit of math I am convinced my case and crank clearances are within spec. This was the machine shop's initial conclusion as well so I am glad we arrived at the same result.



Now just waiting for main bearings, gasket kit, and sealant kit to put this case back together. I already have new chains and ramps waiting.

I need to clean up the case a bit more, chamfer the case through bolt holes, and JB weld this spot under the oil cooler that had a big oil leak during the teardown.



Next Ill need to figure out how to test the oil squirters to make sure they fire.
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Old 04-09-2017, 09:39 PM
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If I didnt mention it before, these are my bibles for this rebuild. Wayne's rebuild book for the general procedure and "how hard can it be?" mentality, the Bentley manual to double check any critical specs or dimensions, and the Bruce Anderson book for background info on performance mods and engine development history.

Lastly is this notebook to record all the dimensional checks and progress. With 2 little ones running around this engine is literally getting built 30-60 minutes at a time and recording all my data is the only way I can remember where I last left off.

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Jose - 1983 911SC Coupe
Old 04-09-2017, 09:47 PM
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Great thread, I really enjoy your attention to detail!

David
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Old 04-11-2017, 08:49 AM
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Time to put this bad boy back together.




Chamfered all the thru bolt holes:



Epoxied all the pressed in case plugs:






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Old 05-22-2017, 08:45 PM
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GT3 yellow main bearings came in.



Decided to do one last plastigage check to confirm my case measurements from earlier.



My 5 year old boss lady making sure I dont mess anything up.



And clearance results are good!

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Last edited by 2jmotorsports; 05-22-2017 at 09:26 PM..
Old 05-22-2017, 08:53 PM
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Made some rod and chain holdin' tools.



Came up on this beast of an airbox in the classifieds. Lets see if we can make it work later on.



Then proceeded to read read read and write a set of step-by-step work instructions on how to seal my case. My brain is hard wired to read these since I came from a manufacturing engineering background and spent a lot of time writing them. Too many parts to put in the case in a short amount of time and I want to reduce my chances of oil leaks in the future.



Besides Wayne's books I consulted this thread for case building steps and this thread for the currently accepted case sealants.
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Old 05-22-2017, 09:45 PM
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Laid out all my parts, tools, and chemicals.





Thought I would channel the late great Chris Cornell to help me get through the superunknown.



Checked crank and intermediate shaft gear backlash. Checked out ok.



Lubed all bearings and did a final install of the intermediate shaft and pump assembly, crank, and #8 bearing.



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Old 05-22-2017, 09:57 PM
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Sh** got real as soon as the sealants went down on the case surfaces. Clock is ticking!



DIY chain tool fail. Should have made it a tad longer. Dont panic it will still work.



Didn't forget any pump seals or unbent lock tabs.



Then madness ensued as I rushed to put the left hand case on and get all the fasteners in and torqued in order. When the chaos settled this was left.



I put the case through nuts on the right side because I wanted them to all be on the same side as the oil cooler ones. I dunno; neurotic I guess.



My work instructions saved the day.



Important final step.


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Old 05-22-2017, 10:09 PM
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I love it.
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Old 05-22-2017, 10:59 PM
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Awesome first time rebuilder thread !

Any chance you could share that worksheet ?
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Old 05-22-2017, 11:46 PM
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I like the way you work. Would you like to share your build instructions?
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Old 05-23-2017, 12:59 AM
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nice!
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Old 05-23-2017, 02:47 AM
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Pmax, Dennis, would be glad to. It is an excel doc so you can edit to your liking. PM me your email and Ill send it over.
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Old 05-23-2017, 07:24 AM
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Quote:
Originally Posted by 2jmotorsports View Post
Pmax, Dennis, would be glad to. It is an excel doc so you can edit to your liking. PM me your email and Ill send it over.
You should consider putting a Dropbox or other file sharing type of link in this thread, would make it easy for others to get without bothering you.
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Old 05-23-2017, 01:34 PM
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Originally Posted by TheSt|G View Post
You should consider putting a Dropbox or other file sharing type of link in this thread, would make it easy for others to get without bothering you.
Good idea. Lets try this one: https://www.dropbox.com/s/w247lw5ne2mb6xi/Engine_Case_Assembly_Checklist_170512.xlsx?dl=0

Ill leave it up until my engine is complete.

As usual, these are for REFERENCE ONLY and it is recommended you consult the official factory documentation for all correct procedures.
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Last edited by 2jmotorsports; 05-25-2017 at 09:23 AM..
Old 05-23-2017, 02:03 PM
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Great thread and gives hope to my engine tear down aspirations in 15 years.…curiosity makes me ask why through bolt holes are chamfered.

Good luck and I bet she starts first turn!
Old 05-23-2017, 02:52 PM
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Quote:
Originally Posted by OldSpool87 View Post
Great thread and gives hope to my engine tear down aspirations in 15 years.…curiosity makes me ask why through bolt holes are chamfered.

Good luck and I bet she starts first turn!
Thank you!

Apparently the case hole chamfer along with the existing chamfer in the washers reduces the chance of the o-rings getting crushed against the flat face of the case and possibly causing an oil leak. I cant comment on how well it works but in theory it seems like a good idea. Ill report back with results.
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Last edited by 2jmotorsports; 05-23-2017 at 03:42 PM..
Old 05-23-2017, 03:40 PM
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