Engine Rebuild Update

[gregmarshall]

Just in case anyone was interested and the reason why i've been inactive on the 964 forum, here's an update on my shoestring DIY 964 rebuild. BTW> Can anyone recommend an engineering company for Cam lobe repair?

...What started as a plan to rebuild the engine has ended up being a complete, bare metal nut and bolt resto.

Bare metal respray, repair to rear arches, scuttle, rear window, headlamp bowls, inner sills (still in 2k primer!)
+RS front and rear bumpers

Entire suspension rebuild
New H&R springs/dampers
Powder-coated wishbones + Powerflex bushes
Powder-coated rear trailing arms + Powerflex bushes
Powdercoated ARBs with Pflex bushes
Elephant racing spring plates
Tarrett Engineering drop-links

Brake callipers stripped, repainted with new pistons,seals etc. (Work in progress!)
New brake lines.

Stripped and rebuilt HVAC system (Using a donor unit off a 964 Targa)

Stripped and rebuilt oil system inc new oil cooler, pipework, rebuilt tank with new senders

Top and bottom end rebuild (work in progress!)


here's some garage pictures..

https://www.dropbox.com/sh/q63rm3j3b803bav/LdL4fZL2Aw

Started almost 2 years ago to the day!

Enjoy...

 

[jagman]

Wow, that is amazing. Nice to see someone doing all the work in a relativly small garage and not just throwing a lot of money at a car.
Good luck with the rest of the restoration and keep us posted.

Keith

 

[vitesse]

Fantastic Greg--wondered why we hadn't seen you at Curborough recently--you don't believe in doing things by halves do you.

Keep up the good work needs a lot of enthusiasm to sustain such a big project.

Best wishes

Colin

 

[gregmarshall]

Thanks for the encouragement guys

Next challenges (not including finding the correct size oil line nuts!) are:

1) Have one of the cams repaired (very slightly marked/damaged)

2) Have one of the head-studs removed that has snapped flush

3)Order a single piece of tinware (yes I was lucky on that one- just the rear section!)

4) Order 24x head-studs, couple of timing chains etc.

5) Paint engine fan & rocker covers and get rest of the tinware powder-coated

Amongst a VERY long list of things to do (amongst raising 2 kids under 4yrs.. full time job etc.)

 

[Dekker]

Greg that's fabulous, well done with the project so far and thanks for sharing the photos.

Are those H&R Performance Street coilovers?

 

[Hacki]

ORIGINAL: gregmarshall


...What started as a plan to rebuild the engine has ended up being a complete, bare metal nut and bolt resto.

That´s how it always begins, isn´t it?

Thanks for sharing, impressive work.

Nice calendar also.

Good luck with that project and keep us posted, please.

Hacki

 

[vitesse]

Amongst a VERY long list of things to do (amongst raising 2 kids under 4yrs.. full time job etc.)

Well you'd better start by getting them proper overalls ,some health & safety training including airfed spraying masks & junior spanner sets
After that the job should race along.

And there was me thinking sending kids up chimneys ended in Victorian times.[]

How about getting your "Dad" to help--he's also good at crashing,rebuilding 964's,etc[:-]

 

[mcgc0]

ORIGINAL: VITESSE

...Keep up the good work needs a lot of enthusiasm to sustain such a big project.

And ribbing/advice/comforting/beer/964 parts from his soon-to-be-father-in-law...

ORIGINAL: VITESSE
How about getting your "Dad" to help--he's also good at crashing,rebuilding 964's,etc

You've confused me with someone else Colin...


Dave, you not Register Secretary yet..?

 

[vitesse]

Marcus,

I used to be confused -now I'm not so sure[&o]

 

[gregmarshall]

Which reminds me!

So Marcus... do you still have the main oil lines (thermostat to oil cooler)?

One of mine is leaking from the joint between the hard line and the flexible braided line. This means either:

Replace the braided line with aftermarket hose/connectors
Replace the lines with new ones from Porsche (£400+VAT)
Find a good second hand line (from dad?)

I'm not sure which one it is but I have a vague memory when we were looking over the bones of the grey 964 that one of the lines looked OK????

Thoughts on this?

Also don't forget the RS lights, rear bumper rubbers!!!!! There's a brand new RS light on eBay for £20..usually around £30!!

DEKKER> Yes they're H&R street performance springs..

 

[gregmarshall]

Here's an update on progress:

Found a place down in Folkestone to have the cam repairs done - I got a recommendation off a chap called Rob Beere, based in Coventry who specialises in pre-84 Jaguar race cars. Both cams reground to factory spec for around £250.

Turnaround time - 10 days.

My mate Neil (who is building a supercharged 73' RSR from a 84 3.2) who lives on the next street to me has managed to get all but one of the 4 broken headstuds out of the crank cases and has found an engineering firm in Stoke to remove it for £60. It's snapped flush with the case.

New engine studs, timing chains, rotor arms and distributor caps have arrived but i'm still waiting on one section of tinware.. two weeks.

All the other tinware has been shotblasted
Rocker covers have been chemically dipped and shotblast and etched primed. These are going to be painted Porsche Blood Orange BLUTORANGE as is the fan.


Enjoy the weekend

 

[ray stobbs]

nice one greg thanks for shareing

 

[Dekker]

Thanks again for sharing Greg.

Now I guess you're Midlands based, contact me if you need jobs to be done like regrinding cams as I know a few people in West Midlands who can help, or at least know where that work can be done more locally.

 

[Gazza3501]

Greg
I presume you have checked that the rocker/cam covers are flat. They have a tendency to warp. Might be better with new or billet ones.

 

[vitesse]

Don't think his "Dad" has any[]

 

[mcgc0]

ORIGINAL: VITESSE

Don't think his "Dad" has any[]

Funny man... I can make him some plywood ones if he wants..

 

[gregmarshall]

ORIGINAL: Gazza3501

Greg
I presume you have checked that the rocker/cam covers are flat. They have a tendency to warp. Might be better with new or billet ones.

Yes they're straight and true

 

[gregmarshall]

Funny man... I can make him some plywood ones if he wants..

M> I'm going to make you an 8'x4' Plywood spoiler..