Waterlogged Rust Bucket

[blee]

No sense in going half-way. Hit the exhaust ports too so they now match the headers.

[Jonny042]

I saw that tapered bit and wondered if he made it, or turned it down to fit.

Your "blend" job will be fine. And for sure a huge improvement over an 8mm miss-match!

42mm is a pretty big port, but you have to work with what you have, and matching to the manifolds was probably the right move.

As always, thanks for sharing. It's great to see people DIY'ing stuff like this.

Originally Posted by blee

Funny you should mention - since the motor is a '78 ROW, I too thought it would have the bigger 39mm intake ports - wrong. When I took the motor apart, I saw that the original heads were gone and had been replaced with '83 heads for whatever reason.

Yup, I got lucky. Chief found a tapered bit in his shop that matched the opening so it saved me from a bunch of additional hand massaging.

The thought of my PMO intake manifolds with 42mm openings mating against a 34mm head just didn't seem right, so I opened them up to match the PMOs. I don't have the tools nor the skill to port them all the way through like the $$ pros so I just massaged the taper to make the transition smoother. It's definitely not a full-on 42mm port job, but now the ports match and there is no longer a "8mm lip" for the air to hit - I'm hoping it'll improve the flow.
Do you think it’ll work Jonny?

[blee]

Case cleaning is done.

From this -


To this!

A journey in itself! De-greased, cycled through the parts washer, vapor blasted, then ultrasonic tank. Oxidation on the alloy case from sitting so long was ug-ly.
It's now cleaner than new!

One of the oil squirters also gave me some heartache. It wasn't spraying as clean as the other five so had to let it soak for a good month. Was just about to get it replaced, then after another go with soaking, it finally opened up! Wanted to avoid having to replace it if at all possible.
Happy to report that all six are now spraying the same pattern.


Thanks to this handy Stomski tool.


Replaced all the broken Dilivar head studs too. Installation of the new steel studs was a breeze with this handy tool made by John Walker - thanks JW!


...and just for fun

[john walker's workshop]

Might need that tool back in a week or so.

[blee]

Tool returned.

Heads are done.

Twin plugged, Aasco hardware, new intake valves, guides, bushings, re-faced, & further massaged by Ollie's (They refused to send them back w/o more massaging!)









Target = '74 RSR spec: 2994 cc; 95x70.4; 10.5:1; Valves: 49/41.5; Ports: 42/42.
Fingers crossed to reaching 315 HP/ 313 TQ

[lvporschepilot]

What cam do you intend on running? 313lbs torque won’t be possible but over 300bhp should of you run at least a DC70-80 cam. You’ll need much better rods to spin it as high as it needs to go. I’ve built two 2.8LS engines on 7r cases now using DC65 cams, 39mm and 38mm ports, twin plug with high compression, better rods, and both make about 270-280. Idle is a bit rough but street manners are otherwise fine. For a road engine and 10.5:1 static cpr, DC80 is really pushing it as it’s basically a race cam and IMO that cam needs 11:1+ static cpr.

[blee]

Should have got the DC70s! I'll look into it. Thanks for the recommendation lvporschepilot.

[lvporschepilot]

No no, you will be super pleased with DC60s. Fabulous driving cams with 10.5:1 cpr. You will not be disappointed with that engine. Stock con rods will be a weak point so just be careful. Love your work in this thread btw!

[blee]

[chrisbalich]

my goodness.
I just read this start to finish and I don't have the words to express how impressed I am.
Wow.

[RSBob]

Originally Posted by chrisbalich

my goodness.
I just read this start to finish and I don't have the words to express how impressed I am.
Wow.

How about, You are a god.

[blee]

Rick - you're making me feel warm & fuzzy. Cut it out!

[al lkosmal]

Looking very good Brian.

regards,
al

[RSBob]

Brian, with the temps dropping, you can use the warm of all your fuzzies.

Al is also a small “g” god, or maybe a sub-god but this is not about Al. Now back to our regularly scheduled program already in progress.

P.S.And if one can’t be popular based on ones stellar personality, then relentlessly suck-up.

[al lkosmal]

669

[Bigtoe32067]

I too have just found this thread and read it start to finish and have to say it was the most entertaining thing I've read in a long time.
I have a similarly equipped 3.0 twin plug 10.5 motor and it makes 295 hp. I didn't build it but bought it that way and it's a blast to drive. I have a 2.7 and a 3.0 that I'm about to attempt rebuilds on. I'm in the process of a 914 conversion and originally bought the 2.7 for it but just found a deal on a 3.0 that was running in the car it came out of but I've decided to go through it. I haven't actually started on either yet but I was in the repair business for 25 years and retired a few years ago but have never messed with and air cooled engine before. LS motors and British cars I know in my sleep so I hope I can figure out these engines.
Sorry to hijack your thread with such a long winded way of saying that thanks to your endeavors and this thread I am motivated now more than ever to start my journey and I'll take your advice with regard to the dedicated camera and labeling bags and putting them into labeled boxes.
Please continue with your 3.0 build thread to help us newbies along and I wish I was closer so I could meet some of you guys and go on some runs with you guys. You guys seem very supportive of each other and it's nice to see.
Keep up the good work
Tony

[blee]

Welcome to the journey Tony!
Sounds as though you already have enough projects in queue to keep you busy for a while. With your background, I have no doubt that you'll transition just fine into these air-cooled gems. Lots of resources and great people with knowledge willing to help here.
Buckle-up, it's going to be fun!

[Jonny042]

Brian it's been a while since an update, seems like you had everything on hand to get this buttoned up? Looking forward to the next chapter!

[Trakrat]

Originally Posted by blee

Case cleaning is done.




A journey in itself! De-greased, cycled through the parts washer, vapor blasted, then ultrasonic tank. Oxidation on the alloy case from sitting so long was ug-ly.
It's now cleaner than new!

ok... there has to be more done than what you are saying. Even the OUTSIDE looks like it was smoothed out from something.

[Jonny042]

Vapor blasting will do that.....