Spendo's Engine rebuild.
 

Thanks to Walt at Competition Engineering. I have decided to rebuild my engine myself. Of course Walt will do all the reconditioning but I took it apart and i am going to put it back together. So here's what i have so far.

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Taking the engine out.

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Its out doesnt look bad but has a realy deep knock.

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top

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All that stuff was the engine compartment asfault stuff that was sucked through the fan blower onto and into all the cooling fins of the heads and cylinders. yuck!! no wonder it was running warm.

Not to mention all the oil leaks.

A lot of the 912 engines have "headache", cracks between valve and spark plug opening. It can be repaired/welded and will last for many years.

How is the transmission? With a bit luck some new seals and a can of Swepco will add some years of its service in the 912 or am I to optimistic?

Remember, if you are working on the suspension, that you have to choose for the US or for your car original European riding height.

Do you have the factory manuals for the 912 engine? They are a great help when doing the engine.

Otto

My Transmission guy says it is in great condition. Very little to do. Replacing syncro rings and maybe 1st and 2nd gear. Major gears are great with little or no damage. Pinion gear is perfect. Hot tanking and making it look new again. these are some pictures of it appart. should be finished in a couple of months, I told him to take his time my garage is not very big and trying to time it with the car coming back from paint and engine being finished.
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Engine tin off


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Valve cover off and rockers off, I started on #3 and 4 side of engine and took everything off and then put it back together a couple of times not torqueing anything just fitting and practicing to get to know what i will be doing when i get the engine pieces back. I can't break what is going to be replaced anyway.

Found out engine had been done once before by my parents. Unfortunatly they cheeped out on the rebuild and it is now costing me the pain.

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I placed the head bolts back in place and took this photo.

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Then took cylinders off. found out they were cheep. and will replace them.

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Allthough the case will be bored. Try not to let the rods damage the bore walls. Especialy when you put it back together.

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I layed out took photos and labled every thing i touched. being a first timer on an engine rebuild I did not want to miss anything. Hopefully?

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Unfortunatly I found out the crank is bad, It has been ground twice before.. It looked good to me but It's my first BBQ and I trust my Pro. the cam is bad also so both will be replaced.

Bad news! How many miles are on the engine that is has been ground twice before? In general an original crank can be ground to third undersize. So could a second opinion be helpfull? Investing in a new crank and cam - if not really necessary - is a pricy and radical decision.

Otto

I'm only doing this once. I'm going to do it right. Hopefully :)

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Bad groove cut into the flyweel.

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All boxed up and ready for Competition Engineering. Can't wait to get it back.

Correct! Once and right, that's the way to do it!

Otto

Spendo65,



Great documentation, are you using the Pellow's engine guide to assist you or do you have prior knowledge of how to rebuild?

Keep up the good fight,

Cheers,
Trevor

Sorry, duplicated reply. You gotta love pokey Internet connections.

Trevor,

Good recommendation. The Maestro's books are very informative and great fun to read! I have a set of DVD's with his step-by-step engine rebuild - great info and even more specific humor. He was a unique person.

Otto

I have a porsche 912 Hand book. service manual. and I have a good friend that has built VW racing engines since he has been 16. Although different in ways we can figure it out. I have always love to work on things. I will keep adding photos. I took lots.

Spencer

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This is the Cam gear and the crank. I took this photo because of the importance of where these gears need to be when putting i back together. 0 between two : dots. Don't forget!!

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I took these to remind me of the rubber gaskets that are in each hole and the oil pick up tube needs new rubber also.