Rebuild Time

[pbanders]

I finally took my car in for an engine and tranny rebuild. My engine was last rebuild in '85 and is getting long in the tooth, with low compression, low vacuum, and ever higher HC emissions, as well as various oil leaks and other maladies. The tranny's even older, and suffering from leaks and some engagement issues. As a result, my car sat for a year and a half without being driven. Luckily, all I had to do was charge the battery and it fired right up for its trip to the shop.

I've always thought, "gee, I could do that work myself", but the reality is that I'm never going to get around to it. Way too many distractions - family, work, other stuff, etc. Instead, I'm going for the green solution - money.

Work on the rebuild starts Saturday, essentially a stock 2.0 with Euro pistons and D-Jet. No idea of what the tranny will need, just secure with the knowledge it will be expensive. We're also planning on plenty of cosmetics to make the top/bottom engine compartments look nice. My shop is Stuttgart Southwest here in Phoenix, a shop with plenty of 914 experience. Wish me luck, I'll post pics from the end result.

[nine_one_4]

If you don't mind my asking, how much are they charging you for the engine rebuild? Are they using all OEM parts e.g., sodium-filled exhaust valves?

[pbanders]

I'll let you know when I get the bill

My old mechanic in CA used to always preface any discussion of price by saying: "Well, it's going to be breathtaking". He also used to like to yell at me as I drove away, "There goes your warranty!!"

Parts are as OEM as I can get or better.

[nine_one_4]

Originally posted by pbanders
He also used to like to yell at me as I drove away, "There goes your warranty!!"

LMAO!

[Dave at Pelican Parts]

That was Bob, right? We love him--he is now doing the work on My Attorney's SC, and she thinks he is a hoot! And as always, the work is excellent.

--DD

[galto]

I just finished rebuilding my 914, very interesting to say the least. Rebuilding is time consuming and keeping your shop/garage clean enough with as little distractions as possible is always difficult. But I believe it to be one of the most rewarding things I have done in a while.
Next on the list is to try and get megasquirt to run it.
And I hope to get to the spare tranny that I have. I’ve built engines, but never a tranny, so this will be very interesting.

What are the specs on the rebuild you are going for? How many miles between rebuilds? Will your builder let you know the tolerances that he found (how much wear you put on it)?

Anyway, let us know how the rebuild works out!

[pbanders]

Originally posted by Dave at Pelican Parts
That was Bob, right? We love him--he is now doing the work on My Attorney's SC, and she thinks he is a hoot! And as always, the work is excellent.
--DD

Yeah, that's Bob. Is he still in that shop in the alley?

[Dave at Pelican Parts]

Bob still has the same shop. But he now has two guys that work for him. I think he still does some of the wrenching, but not all of it.

http://www.realmeangarage.com (I think you can see Linda's hand in the choice of URL... )

--DD

[pbanders]

They're starting on the rebuild, finally got to my car. My rebuilder is Jack Doverspike. I'm going for a near-stock rebuild, with just Euro pistons for a bit more power. I'm more interested in reliability, driveability, and smoothness, than I am in power. Oh, and - NO OIL LEAKS. I'm getting everything carefully balanced, all the engine tin is getting cleaned up, fixed up, and powdercoated. Jack said the fan housing is magnesium and cleans up poorly, and recommended powdercoating (though that requires re-chasing all the threads and other details) - any comments on this or alternatives? Any other suggestions on things I should consider having done during the rebuild?

[nine_one_4]

Just curious - is your D-Jet system working well?

[magaoidh]

I would like to know the final costs too,mate!
Geoff

[bowlsby]

If you need a new harness or just yours repaired, you know where to find me....

[pbanders]

Originally posted by nine_one_4
Just curious - is your D-Jet system working well?

Jeez, I sure hope so, just check out the link in my sig !

[pbanders]

Originally posted by bowlsby
If you need a new harness or just yours repaired, you know where to find me....

My harness isn't totally perfect in appearance (some discoloration), but functionally, it's fine. One of your new harnesses is tempting, though....

[swl]

Originally posted by pbanders
Jeez, I sure hope so, just check out the link in my sig !

oh THAT pbanders! LOL

Gotta tell you Brad that your site is a gold mine for anyone trying to figure out D-Jet. Thanks so much for taking the time to share all that research.

Steve

[gregrobbins]

Hi Paul. we've never met in person, but emailed in the past. Jack is a great mechanic. He will do well. I take my 968 to them from the west valley as Joe in the shop really knows the 924s,944s, and 968s.

Oddly, I am having my 2.0L rebuilt right now. I am staying stock except going with the Web Cam 73 grind. My stock cam had some issues and Web said the 73 will work well with D-Jet. I guess we will see. I am having my motor done at Carrolls' Foreign Car in Glendale. Bill, the shop foreman, is a long time VW mechanic with lots of Type IV and D-Jet experience.

Hope to meet you in person some day.

Greg

[djpateman]

I am planning a similar rebuild on a 2.0 with Euro pistons, and a cam/lifter set all of which came from Jake. I am planning on keeping the D-jet also, and that influenced the cam choice.

[gint]

Originally posted by pbanders
They're starting on the rebuild, finally got to my car. My rebuilder is Jack Doverspike. I'm going for a near-stock rebuild, with just Euro pistons for a bit more power. I'm more interested in reliability, driveability, and smoothness, than I am in power. Oh, and - NO OIL LEAKS. I'm getting everything carefully balanced, all the engine tin is getting cleaned up, fixed up, and powdercoated. Jack said the fan housing is magnesium and cleans up poorly, and recommended powdercoating (though that requires re-chasing all the threads and other details) - any comments on this or alternatives? Any other suggestions on things I should consider having done during the rebuild?

They have high-temp silicone plugs for bolt holes that can withstand the heat of the curing oven. There are other ways too. You could plug the holes with just about anything, apply the powder, and then remove the plugs before heating the part to cure the powder.

[Demick]

Yep, what Gint said. Just plug or mask anything you don't want powdercoated. We do that alll the time.

Demick

[jhadler]

Originally posted by pbanders
They're starting on the rebuild, finally got to my car. My rebuilder is Jack Doverspike. I'm going for a near-stock rebuild, with just Euro pistons for a bit more power. I'm more interested in reliability, driveability, and smoothness, than I am in power. Oh, and - NO OIL LEAKS. I'm getting everything carefully balanced, all the engine tin is getting cleaned up, fixed up, and powdercoated. Jack said the fan housing is magnesium and cleans up poorly, and recommended powdercoating (though that requires re-chasing all the threads and other details) - any comments on this or alternatives? Any other suggestions on things I should consider having done during the rebuild?

I recently had my tin powder coated, and they came out GREAT!

I wanted to do the fan shroud too, but my powder coater guy didn't want to put magnesium in his oven. Did have it bead blasted though, and I spray painted it with "aluminum" color high temp engine paint from the FLAPS. It came out looking pretty darn good.

-Josh2