Rebuild update/Guess what's wrong w/head gasket!
 

OK, the rebuild's fully underway. I bought the car few months ago, with the intention that it would cost about 5k being a trackworthy street car. I'm passing through $5500, and I'm not quite done. I think this car would've been junked if it werent for me, so I feel good about that but boy has it taken some work... Anyway I was leaking oil onto the cross over pipe for those who are following. I don't have too much time to type this up now, but I'll go ahead w/the pics, can anybody guess what was wrong?

Few shots of the weird gasket:
http://boards.rennlist.com/upload/DS00017.JPG
http://boards.rennlist.com/upload/DC00025.JPG
http://boards.rennlist.com/upload/DC00021.JPG
http://boards.rennlist.com/upload/DC00016.JPG

The filthy 'problem' head... It had 4 bent exaust valves, and one bent intake valve, completely worn guides, and badly leaking seals. It's off to the machine shop where it'll be cleaned, and will recieve a performance head job, 3 angle grinds, porting, etc.
http://boards.rennlist.com/upload/DC00005.JPG

Cylinders without the head. In this shot you can also see the top of the Koni sport adjustible shocks, and the new strut mounts (which hide the factory sport springs, competition bump stops, new dust boots, etc.):
http://boards.rennlist.com/upload/DC00009.JPG

Another look at the tops of the cylinders. Thankfully mine don't show any noticable wear, or marks :cheers:
http://boards.rennlist.com/upload/DC00007.JPG

Represent! The only two stickers on my car are for rennlist, and PCA
http://boards.rennlist.com/upload/DC00012.JPG

Side of the car, showing off the paint/bodywork:
http://boards.rennlist.com/upload/DC00027.JPG

A closer look at the front end/brakes/wheels:
http://boards.rennlist.com/upload/DC00004.JPG

I'll post more info later, I welcome any comments, questions, etc.
Ahmet

That paint looks great! I wish I had a color like that. I spent all sunday waxing my black, then going around with a toothbrush getting the rest out of the cracks. I truely think your doing a great thing here. Money or not, I am glad to see your getting it back on the road,

True, I for some reason am grateful for that! I mean, it wasn't for you that car probably would have been junked or parted out. Now, because of you, we have another 944 on the road! Thank you!

Scott R, I really appreciate your comments. Also thank you a bunch for that turbo. As always I'm a bit behind in progress... This weekend I helped my buddy clean up the shop, and we didn't get to work on my car. I'm going over tonight at 6pm to put the con-rod bearings and piston rings in. I'm hoping I won't have to get a pan baffle, cause that'll REALLY prolong how long the car stays in pieces... Anyway, even with the current misfortunes the car will probabbly read at my original goal of this weekend. BTW, this is my favorite color on a 44 turbo, followed by champagne.

Overkill, you know I had the dillema of choosing between a turbo S (had to be an 88S in silver), or an earlier model car. I choose the early model for several reasons, the biggest being I drive my cars hard and I'd feel really bad trashing a pristine 88S (couldn't have it any other way!), now I'm not only modifying an early car but I'm doing it on a resurrected car! :)

Thanks for the comments, I'll post updates as the car progresses.
Ahmet

1.2 gees:
Your head gasket and my old headgasket could be twins!
Too bad there's not an "old folks home" for our sad and broken parts!

97XRAY, was your head corroded as well? Just curious...

Anyway, here's an update:

I had good timing, as the rod bearings were worn (not too badly though). And I could see that the pistons had been hitting the valves for a while (valve float), hence them being bent.

Here's a picture (just got done working on it). Re-assembly should start pretty soon. I'm exactly half way through the project at the moment thankfully didn't find anything else broken in there...

http://boards.rennlist.com/upload/DSC00040.JPG

Here's a picture of my buddy Alan melting the exaust bolts with a plasma cutter... Incase you didn't pick up on it, this is really cool!)
http://boards.rennlist.com/upload/DSC00031.JPG

You can see the tear in the headgasket, the tip of my finger is one of the more visible holes.
http://boards.rennlist.com/upload/DSC00045.JPG

And I'll leave you with a picture of myself as I go to watch a movie at a friends house, full day of work ahead of me tomorrow...
http://boards.rennlist.com/upload/DSC00049.JPG

If you have any more questions or want to see pictures of something else, let me know. If I get a chanse I'll try to take a picture of the pistons where you can see the exaust valves have hit (I suspect valve float).
Ahmet

How do the cylinders look?

the car looks sweet - you should have an outstanding ride once you get it all back together.

AFJuvat

Cylinders look really good, there's a pretty minor scratch in the #2 bore, but compression was good in all cylinders so I'm not too worried. The one thing that does worry me (well, OK one of two things) is the main bearings crapping out later as that's the only thing I'm not replacing right now and perhaps getting the timing belt wrong as I just dumped $300 in valves, and more for a head job...
Ahmet

i would not have recognized you from that picture!
make sure to turn the engine over SLOWLY after you set the timing. put it back to TDC and check your marks., you will be OK. I replaced the mains in mine, but i don't think you will have to worry, unless the one that you said was worn spit out metal. I am a little suspect that it did by the scoring in #2 you mentioned. I have NO doubt that it was #2 rod bearing that was worn, even before you mentioned it.

Carter, my worst bearing was not #2 actually (counting from one being the cylinder closest to front of the car, not sure if this is right BTW). It looked like #2 had spun however and recently at that (the crank really is in as new condition though), but wasn't visibly worn any more than the rest of them. One of the bearings (either #1 or #3, I'm not sure) was well worn, but there were no metal shavings anywhere in the engine. I'm not doing the main bearings, hopefully I'll be OK. You saying that you think I'll be alright really does make me feel better...

Thanks for all the replies guys.
Ahmet

Oh, and I'll go over where I pulled each bearing from, and try to take some pictures tomorrow.
Ahmet

Hi Ahmet, hey before you reassemble the engine why dont you think about a crank polish and getting the #2 rod journal re drilled , I am not shure of the company that does it but they do have a race car and after this mod was done they did not have anymore oil related failures.
Also I hope that you dont try to start the car up before you turn it over with the plugs removed to get oil pressure.
if you cant get pressure then remove the oil filter and by hand turn the crank CCwise as you do this pour oil into the filtr outlet, you will need to use about 6 oz of oil then replace the filter, and spin the engine over with the starter motor, till you see the gauge showing pressure, good luck, and I love that color I wish my car was that, you should have a cool ride when your done.....Stan

Hey, you said the oil was leaking down on the cross over pipe? I would like to know if you could tell me just where the leak was coming from, origin? Ive got oil leaking down on mine also, but Ive cleaned the engine and the only place that I can tell it is coming from is the dipstick where it enters the oil pan. It realy only leaks when you bring the turbo up on boost. Im a little stumped? After cleaning the engine there isnt any oil up around the head or anything.

Stan, I'm not in the position to do it right now. I had decided on not doing it before I started the whole thing, but I do appreciate your suggestions it's just that I'm not in a position to do it. I'll be sure to get oil pressure up before I start the car. Do you have any suggestions on breaking the rod bearings/piston rings in btw? I appreciate the compliment also I had wanted a turbo in this color for a long time just not one that needed this much f'kin work!

kcturbo, I had leaks from the cam tower, head gasket, AND the oil pan gasket so chanses are your problem and mine aren't equally bad, my car used some serious oil... It sounds like you need a little o ring type gasket that goes around the dipstick where it meets the oil pan.

Thanks for the heads up and all the replies guys.
Ahmet