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MaxDiesel

Time for a top end rebuild ?

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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:

 

DSC00420.jpg

 

Painted them with Tetrosyl VHT paint and baked in the oven for 1 hour @ 250 deg C to cure (.....kitchen still smells a bit :whistling:)

 

DSC00434.jpg

 

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.

 

DSC00442.jpg

 

ARP head studs fitted:

 

DSC00437.jpg

 

First piston & cylinder on:

 

DSC00430.jpg

 

Remaining cylinders on and starting to look like an engine again :rolleyes:

 

DSC00445.jpg

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Finished the cylinder heads today - new valves and springs fitted - spring lengths set:

 

DSC00449.jpg

 

Air guides installed and heads loosely assembled onto engine:

 

DSC00461.jpg

 

First cam carrier on:

 

DSC00464.jpg

 

Realised I've missed a sheared M6 bolt on the left cam carrier so progress on hold until I get this out.

Edited by MaxDiesel

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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.

 

DSC00474.jpg

 

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... :o 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:

 

DSC00475.jpg

 

The gear even fits !

 

DSC00478.jpg

 

Just need to weld on the ergonomic hande:

 

DSC00481.jpg

Edited by MaxDiesel

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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... :o

 

Specialist :rolleyes: I can't believe the to55ers openly admit to that.

 

All you need are these,

istockphoto_4197823-old-hammer-and-chisel.jpg

and you can be a Porsche specialist too.

 

I'll bet you're glad you are doing it yourself.

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[Just need to weld on the ergonomic hande:

 

DSC00481.jpg

 

 

Spot on Max. A lot neater than my rusty attempt. :ani_clapping:

 

Making things like this give plenty satisfaction when you come to use them. :signs118:

Edited by coxy

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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:

 

DSC00485.jpg

 

Set the timing using the "clamp in place of tensioner" method as per Wayne Dempsey's book:

 

DSC00484.jpg

 

Cam gear tool worked really well :rolleyes:

 

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.

 

DSC00489.jpg

 

Got a few more bits fitted up - decided the orignal cam oil feed pipes look a bit tired so time to email Tripe....

 

DSC00496.jpg

 

Need to get all my tinware down to the powder coaters asap.

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Gorgeous. I look at this thread and wonder why you are not doing this for a living - better than many 'specialists'.

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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:

 

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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):

 

DSC00516.jpg

 

Fitted the rest of the rocker shafts and then rocker covers, also the new cam oil lines (thanks Tripe). Almost oil tight now:

 

DSC00518.jpg

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Few more bits on today: oil cooler, heat exchangers and solid oil pipe:

 

DSC00524.jpg

 

Had my first proper look at the inlet manifolds since the porting work. The runners have been cleaned up and opened out slightly:

 

DSC00529.jpg

 

DSC00530.jpg

 

Main radii have been smoothed & blended. Also removed the casting marks from the main ducts:

 

DSC00538.jpg

 

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 :whistling:

 

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Started building up the inlet system and also installing new seal kits on the injectors:

 

DSC00544-1.jpg

 

Now waiting for all the other bits to come back from the powder coaters....

Edited by MaxDiesel

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This is just beautiful work. I'm not kidding Matt - best I have seen yet :ani_clapping:

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Top job, very clinical (are you a doctor) :signs118:

 

Had mine fired up at the weekend post to follow.

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Got everything back from the powder coaters, went for satin black on the tinware:

 

DSC00545.jpg

 

Fan and shroud are OK, although a bit pitted following the bead blasting...

 

DSC00547.jpg

 

Got the fan reassembled and Loctited togther:

 

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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 !

 

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Fan assembly back on the engine:

 

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Nearly there :rolleyes:

 

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Going to have to start patching up the rear tinware tomorrow - have put it off as long as I can !

Edited by MaxDiesel

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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.

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There's some very talented folks on this site :ani_clapping:

 

'IB Engineering Services' being offered in the future?

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Few more bits done: exhaust & airbox on:

 

DSC00595.jpg

 

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:

 

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After some grinding now matched to incoming pipes:

 

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Attacked the rotten rear tinware piece - aiming for the "functional" fix (can't compete with TB's efforts !)

 

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Done - now off to the powder coaters

 

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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....

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Max lovley work.

What have you held your fan centre on with ? it looks like counter sunk allen bolts ?

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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.

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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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