Thoughts as The Rebuild Process Begins

[OK-944]

I knew from the outset of my ownership of this car…after having reviewed the car’s history, and the fact that the P.O. (who’d owned this car for 25 years) had, on several of the service forms, actually apologized to the service folks for his being “picky,” and from the fact that this P.O. was so very thorough and yet had always run T-rated tires, with no evidence of his ever having replaced rear brake rotors (which are now a bit thin but still in spec), and that I put over 5K miles on this car while burning less than 1/2 quart of oil…that I could likely have simply kept driving it, even at 170K miles.

But as a 65 year old “semi” retiree, with this being my third 944, and while I did an engine drop/complete reseal (plus valve lap) on my previous car (an 85.5), I’ve never gone the extra mile with a complete rebuild. So I want to have this experience…although I’ll admit to this also being a pride-of-ownership thing, as well as a show of respect for what I’ve come to see as a truly wonderful car which has been so egregiously underrated by so many others, who either simply don’t have a clue, are a bit too willful about being overshadowed by the 911 clan (don’t get me wrong, I love old 911’s), or who’s only exposure to a 944 involves an example which had been abused for the better part of its life (very sad yet all too common it seems), but allows this fact to feed into a bias which, IMHO, is completely misplaced. The advantage for me, of course, is that I was able to purchase this ’87 for 4K, admittedly after the P.O. was willing to come down from almost 8K as his priority was to sell it to someone who truly cared about this car’s future. And thank goodness for that!

So I want to do what’s best for the car…and while I’ll go ahead with bearing replacements, I’ll only re-ring if this would be advantageous for the engine. Otherwise, I’ll leave the current rings in place.

I also want to do as much as I can myself - both for the experience as mentioned but also because my budget is not bottomless. Plus, I’ll also be attending to lots of other areas…having already done (and again removed) engine mounts and belts, and having parts on hand like a new water pump, rollers, fuel lines, header studs/nuts, updated PS reservoir…and still possibly needing to purchase (depending on what I find) parts/materials relating to brakes, wheel bearings, clutch components/hydraulics, suspension bushings, etc. etc. I plan to rebuild where possible, replace where essential, all in hopes of coming as close as possible to having this car drive, perform, and behave like it did back in 1987 - and possibly “better” in some respects as certain types of wear-items (like tires) have gotten demonstrably better over the years.

As for sending stuff out…I’m a bit leery of shops that might, by economic necessity, speed through a process by using overly abrasive blast media, some of which might remain hidden in my engine until its too late. Nothing against these shops…but living at I do in rural Vermont…there simply aren’t any shops in my area who can afford to utilize non-recoverable and/or expensive blast media (such as baking soda), nor any who have the equipment necessary to use “exotic” media (such as dry ice). So while I’ve already contacted a shop regarding flywheel resurfacing, and possible (but unlikely in my case) head shaving, I’ll do whatever else I can “in house.”

I also need to be especially mindful of finances in light of our current state of affairs, and that I need to be fully present for my wife - a Nurse Practitioner who is, right this very minute, very hopefully fully protected as she tests and treats patients for Covid-19. Each of us became symptomatic last week, but have tested negative and now feel better. I can only hope that our luck holds out!

At any rate…as I’m currently nearing the end of what has become a huge, DIY installation of pine v-groove to our 16’ vaulted “great room” ceiling (alternately keeps me young and makes me old!), I’m feeling very encouraged that this process is now nearing completion (see photo) and that I am, finally, beginning my transition into the engine rebuild, with my aim to do this and anything else that needs doing…so I can get this ride back on the road and into the twisty’s before the snow flies once more!

Finally, a huge “thank you” to folks on this forum for your continued help and support…and know I’ll have lots of questions as I proceed with this. In the meantime, I promise I’ll do my best to post updates …with photos!

Photo of v-groove ceiling installation, nearly completed:

[jjeffries]

Excellent post. As I've noted elsewhere, I bought my 82 SC with the engine already disassembled, but found rebuilding it to be hugely satisfying and a real learning process. With 180K miles on it, and having always been maintained, the main bearings were pretty much as-new; the rod bearings I replaced but they weren't terrible ... only the oil pump/intermediate shaft bearings showed any copper. Point being: Porsche makes serious engines that, if maintained, last amazingly well. I believe you will enjoy the rebuild.

In regards to getting any subcontractor work done, maybe RPM Engineering in Vergennes could share their Vermont contacts? Might be worth a call.

Safe and kind wishes and a special "Hello & Thanks, We Appreciate You" to Mrs OK-944.

John

[OK-944]

Thanks John...and also for the tip about RPM Engineering...and especially for your kind regards to Mrs. OK!

[911tracker85]

seems like I keep finding threads where John has been before.....

good luck on your project. putting the accessories on my 951 motor I rebuild. hoping to get it in the car shortly and hoping I did not mess up anything.

I took my head to a machine shop as it needed exhaust valves, valve guides, springs, and had it milled.

and my 'creature from the black lagoon' (87 924S)sits patiently in the lot for me to resurrect it. but finishing the 951 and getting the 911 tub primered are priorities. and getting my friend's 84 944 on the road. got it running a few months ago and just finished the TB/WP/seals/etc job.