It lives Egor it LIVES !!!!

[Laurence Gibbs]

Ok a bit melodramtic but engine is now back in the car and the vid shows a quick fire up. Still a fair few biits to go back on but all looks good so far. When i have time i will try to upload the build pics onto photobucket or similar.
http://youtu.be/pbm29AP-nhA

You will notice in the vid i keep the revs up. With fresh rings needing bedding in I did'nt want to leave it idling for long.

 

[Laurence Gibbs]

Here is a pic. Still a few bits to fit before finally finished.

 

[ChrisW]

And you do this stuff yourself --- it would terrify me even if I would love to be able to do it !! []

 

[clubsport]

Well done Laurence!

Are you planning on submitting a detailed article to PP?

If not, interested to hear more about what was found, how extensive the rebuild was, any problems and expense etc..

Look forward to seeing it on the indy after the tedious running in procedure.

 

[h_____]

Excellent work - I'm truly impressed, its great to see people get very hands on with their cars. thanks for sharing, keen to see more pics.

 

[RSGulp]

Good work Laurence! I once built an engine from scratch for an air-cooled VW but I wouldn't know where to start with a 964 motor. Now I think I'd hand it over to the likes if Bob Watson.

 

[Laurence Gibbs]

Thanks for the comments chaps.
Clubsport, I haven't totalled it up to be honest but the rough costs are
recondition heads including new exhaust valve guides and 3 angle valve job, vapour blast
check & clean barrels and Pistons
repaint all tin ware
vapour blast fan and cowl
new rings
all handled by Nick Fulljames at Redtek came to £1500 approx
then
new top end and bottom end gasket sets (top end genuine from Porsche and bottom set from Reinz (jerry woods) with Viton seals
titainium valve spring retainers and sport spring set complete
ARP rod bolt set all from either Porsche or EBS racing £1400 approx
main bearings , rod bearings, sealants , nuts bolts, shims, washers oil, filters, etc probably £800 +
+ a bunch of stuff i've probably forgotten , like fabricating some tools etc

I would guess around 4k ish. bearing in mind I had good crank, Good B & P's and sound case. You could easily triple it and some if you needed any of those.

 

[Laurence Gibbs]

some low res pics . Here is how far I went !

 

[Laurence Gibbs]

here is a titanium retainer on the scales. From memory a standard retainer is almost double the weight.

 

[Laurence Gibbs]

Build up shot

 

[Laurence Gibbs]

Getting correct shim depth. There are many ways of doing this. I do it this way.

 

[Laurence Gibbs]

C clip tool . My god those things are a pain. I ended up making this, which i suppose is similar to the factory tool. It's a 20mm plumbing coupler with a hole cut out out and filed. It works a treat. You can see what a tight fit the C clip is. For the less technically minded the C clips hold the Gudgeon PIn (wrist pin) in position on each piston.

 

[Laurence Gibbs]

Thought this is worth seeing. A full Top end gasket set from Porsche. You end up with a virtually empty box when finished. Only a few gaskets get left in the box, namely ones that aren't part of RS spec Power steering pump seal etc for LHD RS.

 

[Laurence Gibbs]

Sport spring on left and original on right.

 

[Laurence Gibbs]

picture shows 3 of refurbished heads back from Redtek.

 

[Laurence Gibbs]

Most things came out within tolerance with exception to the exhaust valve guides. bearings were replaced as a whilst i'm there thing. The engine in general was in pretty good sshape as a 55k miler should be. It only came apart to cure leaks that were part of old age. The decision to strip the engine completely was really because once down to the rods poking out of the case there isn't much more to come apart so i went ahead and did it. I did not want a nice fresh top end only to find something go leaky on the bottom end a few months later. There is however a lot more work involved when putting it all back. Plus i would not have wanted to try and put the arp bolts in without splitting the case.
Picture shows rod bolt being fastened using the ARP recommended way of measuring stretch.

 

[Laurence Gibbs]

Interestingly there were signs the engine had been apart before with evidence of a likely over rev. Fortunately the repair work had been very thorough. I bought the car with 28K on it so the seals were all likely not as old as I thought.
pic shows engine coming together

 

[Laurence Gibbs]

I found a few of the documented rebuilds on Rennlist quite useful whilst doing the build. I had forgotten how much information is spread across so many areas when trying to get accurate data such as torque settings or assembly methods. You cant simply use one Porsche book to get all the details.

 

[h_____]

Oooo - confirmed beyond my capabilities. That really gives a flavour to what you did. Silly thing to say, as I've got build photos from my engine build done by my indy, and I saw it in bits. But seeing this, brings it home as to what you did.

I would *love* to be capable and brave enought to have a go, but like Rich, havent ventured past something worth few hundred quid.

I remain very impressed.

To query one point alone, you got the ali parts vapour blasted? Was it expensive, how does it compare to Soda blasting - is it more gentle? did you get the heads and block blasted too (they look very clean).

 

[clubsport]

Tks for the update.

Very detailed and extensive Laurence.

I would also be interested to hear more about this vapour blasting?

From memory weren't you running the standard ecu?

Did you get a pre rebuild dyno plot at all?

We have to assume the engine was down on power from standard with the wear etc....

What do you expect or hope for power wise once it's run in?