928 engine block

[fras]

Is there way to repair, weld or sleeve my 1979 engine block, The cylinder walls are corode about half way trough where the head gasket sits.Mybe there is web site who sells Porsche alumina engine blocks?

[rhjames]

yes, you can sleeve the block, but typically, the 4.5L blocks are just throw aways. 4.5L pistons are expensive new and may be hard to find (unless you re-use you current pistons), and if you are putting steel sleeves in it, the cost of the sleeves and machining the block doesn't make sense compared to a short block upgrade.

Most folks will upgrade to a 4.7L or 5.0L block and it's associated parts.

If you want to go the 5.0L route, I believe Mason at WorldWide still has a couple of 5.0L blocks for about $250 each.

you would then need the rotating assembly, and the pistons would need 16V notches cut in the tops, creating what we commonly call a 5.0L hybrid (uses 16V heads, cams, and intake/fuel system).

Many have done this before.






--Russ

[rich]

If it's the top of the cylinders you will need to deck the block. This is a lot of work. 4.5 pistons and rings are crazy expensive. You would be better off getting a better block. There are seems to be 4.7L and 50.L blocks available.

[Danglerb]

Depending on your location it may be possible to find a running used long block for around $500 or less, they are not a very high demand item as generally the motors last a long time.

Sounds like the PH on your coolant went bad, so you might have damage in many other places.

Did you test the coolant for PH?

Have any pictures?

[rhjames]

if you want to stay with the 4.5L, and you're in the south Texas area, I have a spare one---for sale cheap---short block with all the pieces there, just the pistons/rods disassembled




--Russ

[toofast928]

I also have a short block ready to go. Just the block. I'm in the NJ/NYC/CT area.
Tony

[fras]

here is the coroded block,Where abouts is the "Mason at WorldWide?Do you have to do anything with intake fuel system if i upgrade to 5 liter to get more fuel in it? "

[fras]

I will do upgrade to 4,7 liter if i get the know how to do it.

[MPDano]

Wow, I think I had your twin engine in my 928

[Danglerb]

Fras, two questions;

Do you have the tools and skills to assemble a motor? If not you should consider buying a running motor and doing a swap which is MUCH easier.

Where are you located?

Mason is in PA, I think.

[fras]

Yes i had fixed SEL 500 motor before,I will sleeve the engine with Cast iron, The sales man says i need special ring to run on iron as hi sells only the original which are meant for alumina,Will i break it again if i use the rings?I am in Australia

[rich]

Originally Posted by fras

Yes i had fixed SEL 500 motor before,I will sleeve the engine with Cast iron, The sales man says i need special ring to run on iron as hi sells only the original which are meant for alumina,Will i break it again if i use the rings?I am in Australia

I don't think the iron coating on the piston will work with the iron sleeve either. I think the expansion rate of the piston and cylinder will cause problems.

Seems to me I remember reading that there is a alusil sleeve you can have installed in the same manor as the cast iron one. If you really can't find a replacement engine you may want to check into that option.

Personally, I would never repair a block with that much damage to the head mating surface. I doubt your machine shop will be able to bore out the block and press in a sleeve without the existing cylinder splitting where the corrosion has eaten away at the block. When they press in the sleeve they will also need to deck the block. Then you will need to use thicker head gaskets. Better be sure they are available before spending money on this block.

I have shave heads. I ended up using Cometic brand head gaskets. The will make them up for you but I'm not sure that make them for the 4.5L bore size.

http://www.cometic.com/

Good Luck

[Danglerb]

Originally Posted by fras

Yes i had fixed SEL 500 motor before,I will sleeve the engine with Cast iron, The sales man says i need special ring to run on iron as hi sells only the original which are meant for alumina,Will i break it again if i use the rings?I am in Australia

Sleeving your motor is the most expensive and most risky path, with the least upside chance of success or reliability, do let us know how it turns out. The two people I know of, Todd and Mike Simard (?), have full cnc machine shops with many unusual resources.

[MPDano]

Wasn't there some sort of iron sleeve that Carl did? I seem to remember reading an article on Bannlist.

[MPDano]

Here is the thread:
http://forums.rennlist.com/rennforums/928-forum/468373-sleeving-the-928-motor.html

Here is the pricing:
http://www.928motorsports.com/parts/cylinder_sleeves.php

[rhjames]

Fras---

as you are down under, you should contact Greg Gray there in Australia.

he is very knowledgeable with 928 engines, and probably has a solution for your block issue---replacement or sleeving, although from your photos I would replace, not sleeve.

you can reach him at

greg dot gray (at sign) optusnet dot com dot au


He should be able to help you....





--Russ

[rhjames]

Originally Posted by MPDano

Wasn't there some sort of iron sleeve that Carl did? I seem to remember reading an article on Bannlist.

Leo--

if you look closely at the fras photo, you will see deterioration on the top side of the liner, on the outside edge.

this may prevent "dry" sleeving, although Carl or any competent machinist would OK it or not.

Judging by what I see in the picture, this block would not be a candidate for sleeving, unless you went to a wet sleeve (Todd's, Simard's, or Darton MID).

He would be better served by trashing (re-cycling is a better choice--makes a good beer can or two) this one and starting over with a good block.






--Russ

[rich]

Originally Posted by MPDano

I seem to remember reading an article on Bannlist.

coffee out the nose on my desk!

[rhjames]

as a follow up to this:

shipping a 928 short block from (Houston, TX) USA to Sidney, Australia---

if the engine is completely purged (of all oils, anti-freeze, and grease),

shipping costs to Sidney would be---

$687.80 air freight

$181.00 fuel surcharge

$27.15 security fee

$35.00 airline delivery

total 930.95 plus crating (must be on HT wood to ship to Aus--addt'l cost to be determined)

engine shipments maybe restricted into Aus.

All shipping charges USD effective 1/13/09

Fuel surcharges change daily, to be determined day of shipment

[quote from D. James @ gfastusa, Houston, TX]



As you can see, it will be better for Fras to get another engine from someone there in Australia.

However, if you want one, I have one. Total cost would be near $2K by the time I clean, re-assemble, pack and ship.



Your call.






--Russ

[MPDano]

You guys always seem to get me back in line. I missed the damage on the Engine Block, great eye! I also missed the Down Under location. Sheesh, I am getting my speed reading lessons $$ back