I'm continually impressed by this thread. Particularly how quickly you seem to be going. Not many DIY'ers can say they have rebuilt a motor in the matter of a few weeks.

After the short block is assembled and there is more space around the garage, I'll have to clean the last few parts (cylinder heads, valve covers, etc.) so that will take some time. I'd be happy if it's done by the end of January. That'll give me enough time to bring the Cayman back and work on prepping it for next season.

What shape is your motor mount bushing in?
 

Mihnea,

What shape is your motor mount bushing in? Pelican and others sell just the bushing to be pressed in. Likewise the trans axle mounts can be replaced by ones from the 996. Porsche charges a lot of money for the 986/987 bracketry.

I presume your tool suite pops out the circlips?

Did you notice any additional wear on rod bearing #6 since it is the furthest from the oil pump?

Good Luck and have a Happy Holiday. Go easy on the fumes,

Rob

Rob -

The engine mount is fairly new as I just replaced it this past spring. I have been getting just the mount inserts from Pelican for my Cayman as well as the Boxster. On the most recent update, I went ahead and purchased a press so I could press the new mount in myself. (I think I saw one of your articles on the Wevo mount way back and you had a press, so...) In the past I used to bring them to a shop.

I don't have a special tool to pop the clips out with. I just used a small screwdriver and kept my finger on top of the clip so it wouldn't fly across the room, or my eyes, when released.

The thrust face on the #6 rod bearing was the most worn of them all.

Happy Holidays!

Today we joined up the half cases and completed the piston installation. Last image of the 1 - 3 case.

http://i983.photobucket.com/albums/a...psxekq9l9d.jpg

Ion added the Drei Bond, but I didn't take any photos because we were in a rush to complete the installation within the 5 minutes specified before the sealant cures. Here is the 4 -6 case bolted down. Some advice is to use a thin sharpie to mark where you want the Drei Bond to go according to your manual. Then, you can just follow that line while squeezing out the Drei Bond.

http://i983.photobucket.com/albums/a...psfilh7328.jpg
http://i983.photobucket.com/albums/a...pscauhga2u.jpg

Getting ready to install piston #6. Set crank pulley to U6.

http://i983.photobucket.com/albums/a...psng5m2zol.jpg

Here is our piston compressor. Piece of crap. I would go with Martin's suggestion of getting a fixed size one. This one was troublesome to work with.

http://i983.photobucket.com/albums/a...ps0cg8demw.jpg

#6 done.

http://i983.photobucket.com/albums/a...ps6nyf6ygw.jpg
http://i983.photobucket.com/albums/a...psda8270d9.png

Getting ready to install piston #5. Set crank pulley to U5.

http://i983.photobucket.com/albums/a...pstgvqy1bj.jpg

#5 done.

http://i983.photobucket.com/albums/a...ps0b63f1d3.png

Getting ready to install piston #4. Set crank pulley to U4.

http://i983.photobucket.com/albums/a...psgznge0y7.jpg

#4 done.

http://i983.photobucket.com/albums/a...ps9qji7xfp.jpg
http://i983.photobucket.com/albums/a...ps56302c13.png

As it sits at the end of today.

http://i983.photobucket.com/albums/a...ps1zf1nekp.jpg

Next up is the completion of the short block. We need to finish up the sump, IMS flange, and oil pump console installation. Most of those parts need to be cleaned too, so it'll be a bit of work.

http://i983.photobucket.com/albums/a...psda8270d9.png

Money shot!

Well done, brother! That's awesome.

Thanks guys! It should be smooth sailing from here on out until we get to the timing.

Mihnea,
Nice work. The circlip installation is what spooks me on a rebuild but you made it look easy. Have you seen the Youtube multi-part video on 986 engine rebuild? He goes through setting the cam timing sort of quickly but with your tool set it should doable.

+1 on the press. I originally got it to service the many Volvo suspension bushings in the family fleet. There is only so much you can do with a bench vise. My Harbor Freight press needed an intervention by my local machine shop after I bent the top piece above the bottle jack. The jack was stronger than the top structure. Now it is stronger than the jack.

Rob

Yep. That guy is awesome - especially since he tackled the rebuild early on when there was a lot less info about it out there and made his own tools.

The circlip installation is fine once you practice and increase your confidence. Ion and I spent a while practicing installing each piston on the 4 - 6 case, in my kitchen, making sure to (1) index the tool for correct circlip orientation and depth and (2) also figure out how to use the bore scope for circlip orientation and assessing proper installation. We used both the indexing and the bore scope for added confidence. With regard to the actual insertion of the clip using the tool, we never had any issues with a circlip not being seated properly. Including pistons 1 - 3 and the practice we did on 4 - 6, we installed 15 circlips and the installation was perfect the first time, every time. Finally, say you mess up - what's the downside? Just a little wasted time as you quickly unbolt the case and clean the sealing surfaces again. Assuming that you do the piston installation right after joining the cases, the sealant should be easier to clean as it wouldn't even be fully cured. This thought process gave me more confidence in tackling the job. With your level of experience, I think you'll see it's a non-issue once you practice once or twice.