So many damn leaks- down the rabbit hole I go

[b5aar]

Hey Ken I have injector blocks stock and billet I think...also have several porsche specific and stomski assembly/measurement tools when you get there if you need them

[b5aar]

[flightlead404]

I've designed a low-cost block to use as your 3rd and 4th hand with a carpenters straight edge for checking cam sprocket parallelism.

I'll send you one if you give me your feedback when you get to that point.

[speednme1]

Originally Posted by gsxrken

Also taking the opportunity to soak my injectors. Will check spray pattern after a few days of soaking.



Got the shroud in the parts washer. This thing was FILTHY topside and underneath. I thought about getting this re-painted, even with a spray can, but it came out clean enough and is hidden enough it’s all good now.



One of my CIS plastic blocks is eroded. Another is borderline... going to have to source another one. LMK if anyone who went EFI has any laying around.

Ken I'll check my basement tomorrow when I get home and let you know. I think I may have all six.

[gsxrken]

Back from the Mecca - will post more later.
Met with Yoda, picked up my bottom end stuff, and absorbed much knowledge- I gotta write it down while it’s fresh.



Peter Dawes and I sorta maintaining 6 ft social distancing. You can tell the barbershops have been closed around here for awhile now.

[gsxrken]

So a few pics of the jewelry. Dawe’s actually test fit and verified all bearing clearances- told me not even to use platigage- it’s done. Of course I have to trust but verify, but I expect no issues. I need to do a bunch of final cleaning and I can begin the case assembly. My Pelican order shipped in 3 waves and wave 3 should land Tuesday.
Cams rockers should be tomorrow and cgarr says he’ll finish and ship the heads by the weekend. Trans is still up at Kevin’s waiting on third party shipping of some expensive innards; I’m just doing kegel exercises to get ready for that bill.

[gsxrken]

I need to obtain a piston ring file tool. These ones are file to fit each cylinder. Looks like there’s some manual ones on Summit and Jegs for roughly $50. My old machinist retired, another one I used moved to SC, and the third one died of PC so I’m not going to be able to use one of the nice electric ones I’m familiar with.

[jwasbury]

Hi Ken. I bought one of the hand cranked ring filing tools from Summit when building my 930 engine and found that using small “jewelers” hand files was much better.

Also, if you need assembly tool loaners I got ‘em. Have the Stomski cam holding and tightening tools as well as the sprocket alignment tool.

Looks like you have other offers for loaner tools also, so you have options.

[gsxrken]

So much of building this engine is logistics planning. I have received my cams and rockers back from Dougherty (camgrinder), ordered a bunch of new hardware from BellMetric, oil pump IS shaft bearings I had overlooked, plastigage from autozone, 10 cans of brakekleen and kimiwipes, and bought another table to aid in parts layout and assembly.
In other words, I haven’t even started but I’ve been busy as hell.

I am also extremely grateful to Adam (b5aar), one of our 930 turbo board members here and a brother from another mother. Adam shipped up a treasure trove of stomski tools and other precision tools I otherwise was going to have to figure out. He even threw in his original injector blocks when he heard that mine were all cracked. Humbled/amazed/super-stoked.

Jacob with advise, tools offer, and inside track with Dawe’s was invaluable.

Rich (Rich76_911s) totally hooked me up with another brand new injector block and refused to accept even shipping costs for it.

Turbokraft Chris has been in the background and Paul K has offered encouragement and phone advise as well.

I thank you all and hope I can somehow repay or pay it forward in the future. We have an amazing community here.

[TurboKraft]

Originally Posted by gsxrken

I am also extremely grateful to Adam (b5aar), one of our 930 turbo board members here and a brother from another mother. Adam shipped up a treasure trove of stomski tools and other precision tools I otherwise was going to have to figure out. He even threw in his original injector blocks when he heard that mine were all cracked. Humbled/amazed/super-stoked.

Adam "the chain breaker" M. (b5aar) is good people for sure.

[b5aar]

Happy to help Ken - the switch you sent got me out of a jam. Also very much appreciated you sharing your experiences and thoughtful approach to repairs and mods. Got me motivated!

I've gained so much from the members here in knowledge and passion for our 930 addiction

Chris.. thanks for the good word!

After the apocalypse, with whiskey in the jarro, i will tell the chain breaker story

[gsxrken]

A few quick updates, mostly good.
I’ve spent hours cleaning an already clean case and crank, and then more hours in assembly and disassembly with plastigage to verify what Peter Dawe already told me. Everything checked out dead-on.

Transmission cases ugh has to go out to CMS for some sleeving. Kevin said the races were too loose. I don’t have a final tally but this is not the synchro and dog tooth drive by rebuild. It is what it is and no use half-assing this (or anything else for that matter).
https://californiamotorsports.net/products/cms-930-gear-housing-bore-repair

Oil cooler flushed out and holding 41PSI for 2 days. Thanks Adam!


Swapped out my fuel lines from tank to fuel filter with Len Cumming’s most excellent kit. I do have a new accelerator cable boot ready to go, along with the two transmission boots. Charlie Griffith has said this is a huge leaky area for outside air and add a few degrees to your cabin temps FYI.




Got my engine tins etc back from powder coating and had the AC bracket silver cerakoted- looks fantastic too bad it’s 90%hidden.


Fan housing is cracked- magnesium welding is not my thing so off to a friend to try before I spring for a reproduction for another $825 (!) part that doesn’t even make my car faster... https://www.pelicanparts.com/More_Info/93010600607EPS.htm?pn=930-106-006-07-EPS



And lastly, waiting on CGarr for my heads and flywheel. He said he was slammed and the whole world took the virus quarantine as an opportunity to send their heads to him, and I guess that was true. Hopefully they go out soon. I will have the case buttoned up waiting for them by mid week so the timing probably adds a week.

[gsxrken]

The other battle- and battle is the right word- was with the oil lines to the thermostat for the front oil cooler.
One look at the steel nut to the aluminum thermostat and I knew it was going to be trouble. I had hit it with PB Blaster a few days ago but I didn’t even bother trying with the wrenches. First thing I did was get the torch and cherry-up the nut. In a rare failure for the fire-wrench, that did not work. I was putting way too much torque on the nut - there’s not an easy way to hold back in an opposing way - and it still did not break loose. I ended up using a whizzer to cut through most of the threads, went further with the hand hacksaw, and then air chiseled the slot in a CCW direction and got them loose.


No thread damage. But turns out Mobil 1 15/50 stinks worse than LSD gear oil if that can be believed if it gets over 400*F like it did when that nut was glowing. Just got back in from supermarket and the house reeks of it.


Here they are on the ground. No doubt they were accessories to the leakage. Good riddance.


Here is the assortment of tools required for the job. Not a trivial one at all. Go slow

[Rich76_911s]

Looking good!!! Those oil lines are always a pain in the butt.

You’re going to lap me. I’ve hardly started mine other than measuring and cleaning.

[gsxrken]

Originally Posted by Rich76_911s

You’re going to lap me. I’ve hardly started mine other than measuring and cleaning.

Thanks again for that injector block! Don’t be too hard on yourself- measuring and cleaning is 90% of rebuilding one of these. Without exaggeration, with the cleaning and plastigage assembly/disassembly etc hours I have into this, I could be done already if I skipped those steps.

[b5aar]

Damn...fire AND air chisel

The power of German beer compels you!

[gsxrken]

Got my heads back from CGarr. Look sweet! He had to change intake valves (TRW) but exhaust ones were ok. Those things must be amazing to last 100k miles.
Light resurfacing and the usual guides and seals. Also had him skim my flywheel for a new clutch. Great guy to deal with.

[gsxrken]

I’m sort of all over the place right now. Hiccups in the delivery and part sourcing permitted me to get into the reason for a slow window on the passenger side. These things are a pain in the ass

[Bucketlist]

Originally Posted by gsxrken

Got my heads back from CGarr. Look sweet! He had to change intake valves (TRW) but exhaust ones were ok. Those things must be amazing to last 100k miles.
Light resurfacing and the usual guides and seals. Also had him skim my flywheel for a new clutch. Great guy to deal with.

Look nice, but I would have gone twin plug while I was there. Has saved my a*s several times.

[gsxrken]

Originally Posted by Hot Euro

Look nice, but I would have gone twin plug while I was there. Has saved my a*s several times.

Actually didn’t give it a second thought. This isn’t my “fast” car, and I’ve done a very good job (for me) restraining myself from going down that lane with it. My future plans for the car will work within the constraints of the factory single plug config. Of course everyone has different goals and I don’t blame you for future-proofing yours.

Big day yesterday- got the case buttoned up. Nerve racking because there’s a lot of things to track, and a lot of things that could go imperceptibly wrong. Son #2 came in huge again. I used and followed Henry’s sealing method and products. I hope all my oil pump and case o-rings were trapped properly. I hope my case sealant squeeze out was sufficient- we finished right at 45 minutes. I hope my intimidating #8 bearing o-ring and seal do seal... if it doesn’t I don’t know what I’d do differently and a total tear down and re-splitting the case would be unfathomable.

Next on the list it to read a metric ton on cylinder, head, and cam tower sealing. It’s a sickness.




-