ChrisD (RIP) Posted February 21, 2009 Posted February 21, 2009 Great job Matt - really interesting to follow the thread. Ever thought you might be doing the wrong job? Chris D.
MaxDiesel Posted February 21, 2009 Author Posted February 21, 2009 Thanks for the comments guys Ever thought you might be doing the wrong job?It reminds me why I got into engineering in the first place ! Made some more headway today, attacked the cylinder air guides with Nitromors and then bead blaster: Painted them with Tetrosyl VHT paint and baked in the oven for 1 hour @ 250 deg C to cure (.....kitchen still smells a bit ) Got a few more of the case odds and ends fitted and then started on the cylinders. Checked all rings gaps with new rings - all to spec, then assmebled the pistons into the cylinders on the bench. ARP head studs fitted: First piston & cylinder on: Remaining cylinders on and starting to look like an engine again
MaxDiesel Posted February 22, 2009 Author Posted February 22, 2009 (edited) Finished the cylinder heads today - new valves and springs fitted - spring lengths set: Air guides installed and heads loosely assembled onto engine: First cam carrier on: Realised I've missed a sheared M6 bolt on the left cam carrier so progress on hold until I get this out. Edited February 22, 2009 by MaxDiesel
MaxDiesel Posted February 26, 2009 Author Posted February 26, 2009 (edited) Sheared bolt removed from cam carrier so both carriers now torqued down to the heads with loctite 574 to seal. ARP head nuts also torqued up. Cams installed and turn fine. Hoping to set the cam timing at the weekend so started investigating cam locking tool options (Porsche tool P237). Spoke to a independent specialist to see if they'd lend me theirs and was surprised (& alarmed) to find out they didn't have one but use an impact wrench to tighten... Then tried my local OPC (just for a laugh) only to be told firmly "we don't do that kind of thing". So just spend an hour or so with my mini air grinder and a file creating one from a piece of 2" steel tube. Teeth all cut: The gear even fits ! Just need to weld on the ergonomic hande: Edited February 26, 2009 by MaxDiesel
johndglynn Posted February 27, 2009 Posted February 27, 2009 That takes the shortcake biscuit - you are a beaut mate
tea boy Posted February 27, 2009 Posted February 27, 2009 Spoke to a independent specialist to see if they'd lend me theirs and was surprised (& alarmed) to find out they didn't have one but use an impact wrench to tighten... Specialist I can't believe the to55ers openly admit to that. All you need are these, and you can be a Porsche specialist too. I'll bet you're glad you are doing it yourself.
coxy Posted February 27, 2009 Posted February 27, 2009 (edited) [Just need to weld on the ergonomic hande: Spot on Max. A lot neater than my rusty attempt. Making things like this give plenty satisfaction when you come to use them. Edited February 27, 2009 by coxy
MaxDiesel Posted March 1, 2009 Author Posted March 1, 2009 Tackled the cam timing today - all went OK, not something to be rushed though ! Started by double checking the accuracy of the TDC mark by dropping a probe down onto No. 4 piston: Set the timing using the "clamp in place of tensioner" method as per Wayne Dempsey's book: Cam gear tool worked really well Then fitted the tensioners and double checked cam timing on both sides - exactly the same as with the clamps so not sure whther the clamp bit was worth it. Got a few more bits fitted up - decided the orignal cam oil feed pipes look a bit tired so time to email Tripe.... Need to get all my tinware down to the powder coaters asap.
johndglynn Posted March 1, 2009 Posted March 1, 2009 Gorgeous. I look at this thread and wonder why you are not doing this for a living - better than many 'specialists'.
MaxDiesel Posted March 7, 2009 Author Posted March 7, 2009 Gorgeous. I look at this thread and wonder why you are not doing this for a living - better than many 'specialists'. Thanks John - must admit I wouldn't mind doing another one when I've finished mine. Didn't have a good week at work so progess has been slow..... Gave the outside of my rocker covers a bead blast and then air brushed with laquer: Got some new PRV springs as mine were a little short compared to the spec - was surprised how tired the old springs felt compared to the new ones (new on the left): Fitted the rest of the rocker shafts and then rocker covers, also the new cam oil lines (thanks Tripe). Almost oil tight now:
MaxDiesel Posted March 8, 2009 Author Posted March 8, 2009 (edited) Few more bits on today: oil cooler, heat exchangers and solid oil pipe: Had my first proper look at the inlet manifolds since the porting work. The runners have been cleaned up and opened out slightly: Main radii have been smoothed & blended. Also removed the casting marks from the main ducts: Didn't show much of a difference on the flow bench so not expecting any great gains from this... Gave the manifolds a clean in the dishwasher on the intensive programme - worked a treat Started building up the inlet system and also installing new seal kits on the injectors: Now waiting for all the other bits to come back from the powder coaters.... Edited March 8, 2009 by MaxDiesel
johndglynn Posted March 8, 2009 Posted March 8, 2009 This is just beautiful work. I'm not kidding Matt - best I have seen yet
coxy Posted March 9, 2009 Posted March 9, 2009 Top job, very clinical (are you a doctor) Had mine fired up at the weekend post to follow.
MaxDiesel Posted March 14, 2009 Author Posted March 14, 2009 (edited) Got everything back from the powder coaters, went for satin black on the tinware: Fan and shroud are OK, although a bit pitted following the bead blasting... Got the fan reassembled and Loctited togther: Finished assembling the fuel & inlet system - was glad I'd taken a few pictures of the nest of hoses, pipes & brackets at the rear before taking apart ! Fan assembly back on the engine: Nearly there Going to have to start patching up the rear tinware tomorrow - have put it off as long as I can ! Edited March 14, 2009 by MaxDiesel
AirCooledExcellence Posted March 14, 2009 Posted March 14, 2009 Lovely work! When's it going back in the car?
flatsix777 Posted March 14, 2009 Posted March 14, 2009 Matt Looks fantastic - exceptional work. David
MaxDiesel Posted March 14, 2009 Author Posted March 14, 2009 Lovely work! When's it going back in the car? Thanks - aiming to put it back in the car at Easter then on the road 1st May. Have got quite a few things I want to do on the car before it goes back in: - new gearbox mount plates - new / refurb heater boxes - clean & tidy engine bay - pressure wash and underbody wax rear bulkead - refit oil tank So will be putting a cover over the engine for a couple of weeks while I get this lot done.
SP72 Posted March 14, 2009 Posted March 14, 2009 There's some very talented folks on this site 'IB Engineering Services' being offered in the future?
MaxDiesel Posted March 16, 2009 Author Posted March 16, 2009 Few more bits done: exhaust & airbox on: While fitting the pre-silencer pipe I noticed the flange holes are a lot smaller than the exits from the H/E and cross over pipe - by >5mm, can't be good for flow: After some grinding now matched to incoming pipes: Attacked the rotten rear tinware piece - aiming for the "functional" fix (can't compete with TB's efforts !) Done - now off to the powder coaters Also decided I'm not happy with the paint finish on the fan shroud so that's off again and heading back to the powder coaters....
MrPerkles Posted March 16, 2009 Posted March 16, 2009 Max lovley work. What have you held your fan centre on with ? it looks like counter sunk allen bolts ?
MaxDiesel Posted March 16, 2009 Author Posted March 16, 2009 Max lovley work.What have you held your fan centre on with ? it looks like counter sunk allen bolts ? Yes - just M6 stainless countersunk allen screws. I think they were 12mm long - need to be careful as there isn't much clearance to the alternator. Also had to countersink the hub holes to match. Original rivets are only aluminium so I figured std. stainless screws would be fine.
Lesworth Posted March 17, 2009 Posted March 17, 2009 Everytime I have some fettling thats needed but I can't be bothered, I just look at this thread and get all the enthusiasm back! Any chance of a picture of the much neglected and little understood (by me at least) rear (or front I guess) of the engine?
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