[spiffyjiff]

as some of you know, i've decided to bite the bullet and do a preempt rebuild on my DD/track car. it had 65k miles and 100+ track days, with many overrevs, smoke on start up, and some (valve) ticking, so i felt the time was right before anything else went seriously wrong = more $. there's a lot of good builders around here, no doubt, but i decided to go with Jake Raby in Ga. as he has a GREAT rep, especially re: my year and model. plus, his attn to detail and seemingly endless OCD/AR nature def appeal to me.

anyway, it's going in as a 3.8 but coming out as a 4.0, all the while having many of the inherent OEM weakness addressed, getting battle hardened guts, and getting some bling and upgrades added both internally and to the top/bottom end. i'll post pics and updates as i get them but since i understand very little about engine building or even what i'm seeing in the pics, you all can digest and decipher at will.

here are the first pics from the tear down. upon initial inspec, they are pretty sure the reusables - block, crank - are good but they won't know 100% certain until the final analysis from the machine shop. luckily, the only thing outside of the quoted build cost they have found is that i need all 12 vario-cam lifters but i have heard from others that that is not uncommon.

and awaaaaaaay we go.

back dat ass up!


and so it begins






is that scoring...?


is this the variocam lifter? (i'm so ignorant)




dirty dirty


again, i should know what this is but i mostly don't. it looks copper and maybe bearing related?


the money shot - thank god THIS is reusable!

[BlackTalon]

Holy fuch, that bearing is toast! And that does look like scoring in the cylinder (although better to look when it's cleaned up a bit).

I think it was definitely good that you bit the bullet, as you may have been pretty close to getting some new ventilation holes in the case.

[N0tt0N]

That is one of the chain tensioners, btw, not the variocam actuator. Yikes on the bearing. I told Jake to give you sh*t and tell you he had to take it down to a 2.9l in order to save it

[Dandelion]

Let me be the first to say.....




Cheater!

Looks like you caught it in time - good move on your part.

ed

[VaSteve]

I'm not convinced that's scoring. My 944 cyl looked like that, but you can't feel it with your nail.

[ausgeflippt951]

Right on Chris! Very exciting -- good call with the rebuild. That bearing is totally fried.

[N0tt0N]

Originally Posted by VaSteve

I'm not convinced that's scoring. My 944 cyl looked like that, but you can't feel it with your nail.

Agree. That's not usually were it scores. Also, who gives a shit when you're going up to 101mm pistons/bores

Is that a map of Greece on the piston tops?

[spiffyjiff]

Haha if that is Greece, I'm just glad it didn't ex/implode like the actual effed up country!

[zerogt86]

Is this motor a 3.8 from a 997 C2S? Either way, I'm interested to hear what you have to say about the new engine once you get it back from Raby. Keep us posted!

[spiffyjiff]

yep, it's a 3.8, mine is a '06 C2S.

no real update other than to list out what's included in the frivolous outlay of my child's college tuition and to call out some of the bling that will also be going on/into the (yes, yes, CHEATER!) engine.

the overall Raby experience includes:

• Engine extraction
• Engine disassembly
• Engine machining (to include LN Engineering cylinders)
• Ultrasonic cleaning of all components
• Engine dynamic balancing
• Engine assembly
• Engine installation
• Initial break in service (100+ miles)
• Chassis dyno evaluation without ECU Tuning- (Graphs provided)
• Post-procedure inspection (Invasive)
• Baseline used oil analysis (1 sample Included)
• Full documentation & directives provided via USB key
• Race level dynamic balance (with index)
• Standard chassis dynamometer evaluation (no tuning)

• Reconditioned crankshaft (magnaflux inspected, checked for straightness and micro-polished)
• New Main and rod bearing inserts (non-coated)
• New OEM crankshaft carrier bolts
• New OEM crankshaft thrust shims
• New OEM head bolts
• New OEM head gaskets, custom modified for larger bore
• Flat 6 Innovations (FSI) / IWIS timing chains (all)
• Main and secondary timing chain guide rails
• Timing chain tensioners (3)
• Timing chain rail pads (5 chain only)
• Standard camshafts (reground if necessary)
• New OEM exhaust lifters
• New OEM intake lifters (Vario-cam "plus" extra cost)
• New OEM oil / coolant heat exchanger
• New OEM water pump
• New OEM knock control sensors
• New OEM updated gaskets and oil seals
• New OEM AOS
• Blueprinted OEM main oil pump
• New Porsche microencapsulated crankcase hardware
• New OEM clutch assembly to include disc/pressure plate and release bearing

• Custom JE forged pistons with lightweight pins and low tension rings in 101mm bore size
• Genuine LN Engineering Nickies Big Bore Cylinders
• Smooth-flow spin on oil filter adapter
• Low temperature thermostat update
• FSI / LN Engineering triple row IMS to include sprocket welding and shaft updates
• PC2 Coated Rod and Main Bearings
• Billet Oil Pump Drive
• Performance Valve Springs
• LN Engineering / Flat6 Innovations billet connecting rods
• Stage II cylinder heads using performance valves and components
• Stage II port and polishing of cylinder heads
• Flat6 Innovations high performance intake valve seats

and thank goodness my block, cams, and crank are in good condition/reusable. all i needed was 12 variocams as mine were cracked and they are not incl in the original price. in addition to the boilerplate above, i am adding/upgrading the following:

• IPD Plenum
• GT3 Tbody
• Fbspd headers
• Fbspd sport 200 cats/x pipe
• sending cans to Fister for a bit of a punch
• tensioner/pulley replacements (too lazy to do this myself)
• trans mount (i already recently installed OEM GT3 motor mounts)
• upgrade to CP pistons
• upgrade to hi perf coils (prob not necessary but presumably they can better take the higher HP, compression, spark, yadda yadda than my OEM)

as far as the rest of the topside junk, i am only changing out the starter as of now as that is the (i believe??) worst to get to when engine is in. if my alt or PS pump eventually take a crap, i hope it's a relatively painless DIY.

oh and how about THIS bling.