My 964 engine rebuild (Steve Brookes)

[Steve Brookes]

ORIGINAL: appletonn

Any update Steve?

As you probably know now Nick, there's a good week or so of work left yet which means it won't be at Oulton tomorrow or Wales next weekend.

The good news is that all the new parts have arrived and re-assembly has started.

All the barrels and pistons have been cleaned up and are within wear tolerance:

New little end bearings fitted:

Cylinder heads and valves de-coked, valves re-seated and new guides fitted:

Crank polished (sorry for poor lighting):

New valve cover studs fitted where needed and inserts put in and re-tapped for the engine cover bolts (many had been damaged in the past):

Lots of new parts and seals:

The re-assembly begins:

The car, under cover in the corner, patiently waiting for its engine to be returned:

 

[appletonn]

I did make the point about your car being under a nice cover, whereas mine was shoved out under the trees each day just because there happened to be some 993 RS that received preferential treatment for some reason that escapes me....[8|][]

Apparently you take the boys some cake, whereas i only took biscuits[8|]

Glad to hear your barrels and pistons are in good shape - no mean feat at that mileage![]

 

[BIG UN]

Hi Steve,

I'm watching this post with great interest as I'm about to have a complete engine rebuild myself over the next few weeks.
Just doing some research first after speaking to my Indy on cost and what's involved. Getting as much info as possible will
hopefully give me a better understanding about the way to go, that's why your post and others like it are welcomed and
make great reading. I'd like to shoot a few PM's off to you over the next few weeks as I'd value your advice on a few things if that's OK?

A couple of questions I would like to ask to everyone is what is the best way to clean up the aluminium parts ie. crankcase, heads etc. Chemical/sandblasting? Would you consider any finish, paint/powdercoat on the parts when they are clean? Any advice would
be great.

Thanks

Andy.

 

[Steve Brookes]

ORIGINAL: BIG UN

A couple of questions I would like to ask to everyone is what is the best way to clean up the aluminium parts ie. crankcase, heads etc. Chemical/sandblasting? Would you consider any finish, paint/powdercoat on the parts when they are clean? Any advice would
be great.

Thanks

Andy.

Hi Andy, having all of the engine tins shot blasted and powder coated seems to be a routine 'extra' during the rebuild. This includes any new ones that are fitted as they only come with a minimal coat of paint. Once powder coated their life should be extended more than normal. It's also a good idea to have the engine carrier and bracket for the secondary silencer treated in the same way.

I'll be having the cooling fan cleaned and powder coated and the outside of the upper valve covers. My upper covers were replaced with aluminum billets some time ago because the original magnesium ones had warped.

The aluminum crankcases, heads, timing chain covers, etc get cleaned with organic solvent based cleaners as part of the rebuild.

 

[BIG UN]

Thanks Steve,

Added to the very very long list!!!

Cheers
Andy.

 

[keithy]

Well done, Steve. I've just picked up on your thread. It's a great inspiration to all of us considering investing in a rebuild. The whole job looks really thorough - great photos, very inspiring, especially the cleaned up parts pix....................... Now, where's my chequebook?

rgds
Keith

964 C4 in GP whit

e

 

[Steve Brookes]

Not too far to go now []

Pic from underneath (a nice touch is that they've split the heat exchangers and replaced the aging gasket and bolts that had turned to rusty blobs):

From the top (tins now look new courtesy of powder coating and new inlet chambers are being fitted):

Pic showing the shiny new oil return tubes:

My lower aluminum billet valve covers which have been skimmed to stop them leaking:

Upper valve covers have been powder coated grey:

So has the fan:

Box of new bits still waiting to be fitted:

 

[MarkK]

Looks lovely,like a new engine![]

 

[demonfish]

Looking good steve! be back out on track in no time

 

[Steve Brookes]

Engine is now back in where it belongs:

A much tidier, cleaner engine bay. The aftermarket air con pump is gone and its retaining bracket cut down. The rest of the piping to the front and the air con rad has been taken out which has removed 28 Kg from the car.

The gear box was cleaned up, leaking shaft selector seal changed, new clutch slave, hose and hard line fitted.

After a 30 mile test drive the bottom of the engine is looking dry:

Waiting on the ramp for final checks and some wax oiling before I pick it up next week []

Here's the complete list of what I had done:

Full top and bottom engine rebuild that includes all seals and fluids, cam chains, valve guides, piston rings, cylinder (dialever) studs, oil through pipes and main bearings.

Other new parts fitted were:

Camshafts
Valve springs
Top hats and retainers
Little end bearings
A new rocker
Engine temperature sensor
Starter motor
Gearbox shaft selector seal
Flexible heater hoses for heat exchangers
Power steering feed pipe
Power steering pump belt
Crankcase breather pipe
Clutch slave, hose and hard line
Oil feed hose and pipe
Flywheel and clutch bolts
Engine cowell
Valve shims
Cat bypass pipe
Various inserts machined into covers and cases
Powder coating of tins, valve covers, engine carrier and fan
Rubber intake stacks
Distributor caps
Chain guides

 

[appletonn]

Looking good!

After almost 1800 miles since the rebuild, mine's still dry underneath too []

 

[Steve Brookes]

ORIGINAL: appletonn

After almost 1800 miles since the rebuild, mine's still dry underneath too []

That's EXACTLY what I want to hear []

 

[appletonn]

What you will have to get used to though, is the 'sweet' smell of hot Waxoyl every time you turn the heater on! Starting to fade on mine now. Worth it though for the protection to all of the underside - mine still looks like new. Must admit, I have become a bit anal about keeping the visible parts of the engine clean under the bonnet - even the nicely powder-coated fan![8|][]

 

[vitesse]

Steve,
Looks fantastic-I bet you can't wait to get it nicely run in & then some serious "hooning" as you call it-just think of the peace of mind as you drift through Cascades at next years RS day-pity about the non plastic inlet manifold-but then you wouldn't want to get too anal like someone I know & love.[]

 

[ray stobbs]

hi steve good to hear its alive again bet the bank balance doesent look as healthy regards ray []

 

[Steve Brookes]

ORIGINAL: VITESSE

Steve,
Looks fantastic-I bet you can't wait to get it nicely run in & then some serious "hooning" as you call it-just think of the peace of mind as you drift through Cascades at next years RS day-pity about the non plastic inlet manifold-but then you wouldn't want to get too anal like someone I know & love.[]

Two trackdays already booked and am working on another Curborough day for us....so you best hurry up and find that 993 []

ORIGINAL: ray stobbs

hi steve good to hear its alive again bet the bank balance doesent look as healthy regards ray

Thanks Ray...it's now got that expensive lightweight wallet option fitted []

 

[demonfish]

i took the aircon stuff out a few weeks ago while stripping the car, was amazed at what it weighs, not just that but all the fiddly brackets etc too!

looking good steve!

 

[Steve Brookes]

ORIGINAL: demonfish

i took the aircon stuff out a few weeks ago while stripping the car, was amazed at what it weighs, not just that but all the fiddly brackets etc too!

looking good steve!

Cheers mate....and Chris will be pleased to know that I had the ride height taken up to a little above RS spec []

 

[demonfish]

good - now you will appreciate proper handling

 

[appletonn]

ORIGINAL: Steve Brookes

ORIGINAL: demonfish

i took the aircon stuff out a few weeks ago while stripping the car, was amazed at what it weighs, not just that but all the fiddly brackets etc too!

looking good steve!

Cheers mate....and Chris will be pleased to know that I had the ride height taken up to a little above RS spec []

More and more like deja vu for me...[]