Rebuild Project Update: Almost There !!!!
 

Well, after this weekend the little light at the end of the tunnel is now shinning bright ! Thanks to the help of Charlie and Richard the long block is all buttoned up and ready to go :D :D :D

I've updated the gallery with a bunch of pics so feel free to take a look:

http://www.dorkiphus.com/porsche/mod...view_album.php

Here's an abbreviated version of the weekends events:
Saturday afternoon started with intalling the p's into the c's which went pretty quickly. Next we were onto mating them to the case and once we started heating (with a propane torch) the top of the domes we were able to slide the wrist pins in by finger. A quick call to John Walker verified we could re-use the old wrist pin circlips so a major delay was avoided as I forgot to buy new ones :x

After that we installed the heads/cams (I did not separate the cam towers from the heads) but had a devil of a time getting the end of the oil return tube (in the head) to seat perfectly. Special note: make sure to install any engine tin PRIOR to installing the heads/return tubes because if you forget it all has to come apart :wink:

Next we moved onto the chain housings and got everything put together in there. Finally we were ready to time the cams ... almost 4 hours later at 1:30 in the morning Charlie and I decided to call it a night because we couldn't get it any closer then .001" between the left and right banks. Both sides were still in spec and what we heard/read everything should still be ok.

Today started with installing the pressure fed chain tensioners and then sealing the chain housings. After that it was time to adjust the valves, replace the pulley seal, install the sump plate, install the distributor, mount the fan and insert 2 new exhaust studs. The day ended with installing the new clutch, throw-out bearing and pressure plate.

From here I need to install everything on top of the engine (ie., shroud, harness and CIS) and then reattach the exhaust system. Regarding the tranny I need to replace a few things on the clutch release mechanism and then intsall the new clutch cable.

It's hard to believe that just 2 months ago all this machinery had come out of the car and now I'm close to getting it all back in :shock:

Stay tuned, she'll be back on the road soon ... the first DE of the '04 season is less then 56 days away :)

Doug:

Looks Good !

I guess you have set the "bar" for Mackpipes and his 3.2 rebuild. What was it total... <60 days? How many days did Charlie take...?

That gives Pipes a 64 day window from his drop to the 3/13/04 DE. The race is on!

Jase

Jason - thanks. I'm actually just outside 60 days now but to be honest all I ever hoped for was to be done in time for the first DE. At this rate I might actually have a chance to shake the car down now before that :D

BTW, as you know it isn't just speed that matters ... it's smoothness and consistency :lol: :lol: :lol:

Lookin Good Doug 8) !!!!

This was actually a fun project. My 993 is so hassle free, that I don't get to wrench very much anymore. So it was nice to get two days of engine work in while the lady is out of town. Everyone else who's also doing one of these jobs, please heed Doug's words and say "ENGINE TIN" aloud 3 times before you move onto the next step. It was a real buzzkill to have to take the cam tower off again when we realized what we had skipped. It sure does help when you have the right tools, which we did not for the oil return tubes circlips. And for those of you who have the Island911 valve adjustment tool, believe you me, stainless steel stock makes all the difference in the world. I would have had Doug's valves adjusted in 45 min. if not for the very brittle (and cold) stock that came with the tool. I just love using needle nose pliers to fish chips of that out from under the elephant's feet. I probably broke the thing off 5 or 6 times. It really feels like that old board game Operation.

Great work Doug and team!

impressive! 2 questions: did you powdercoat the engine tin? (i thought you and your SO were going to do this but you said you used "high temp paint). and did you use the Allied machine shop in FC? and if so, are they a good P-car machine shop

Great to see another one buttoned up!

Congrats Doug.

type954 (not sure who you are since your name doesn't appear anywhere) - no powder coating was done on the project. We'll see how the high temp paint holds up ... sure can't be anyworse then what was there before. Only machine work that Allied did for me removing a broken exhaust stud and re-surfacing the flywheel and both of those were very well done IMO.