Engine refresh

[newto912]

So last year after getting the car up and running a valve spring went , I tried to replace it in situ but too difficult and dropped the engine
found that another spring was about to go and the other two on that side were rusty as well
so as it was smoking and I had no history with the car decided to strip it down and go for a refresh
As I have limited experience I took the stripped engine to an experienced engine builder who kindly checked it over
good news
case in good order bores within tolerance
crank is good standard bearings but on the limit of tolerance
con rods,cam gears ,oil pump, clutch all good

needs new pistons/cylinders

so have had the crank reground,polished, and dynamically balanced
new small ends
after doing a fair bit of research have gone for shasta big bore pistons and cylinders
Shasta full flow oil filtration
nuetek SX2 cam and followers to match
still awaiting the heads to return from the machine shop

with the help of secrets of the inner circle, maestro DVDs and a load of new tools and measuring devices,I have started to get it back together
hope to finish it well before Stanford Hall, thats the plan anyway
may need some help here and there

pics as I progress to follow

[mycar]

Sounds like fun !

I didn't know that Shasta did the oil filtering, looking forward to your progress.

[newto912]

Case has had a deep clean inside and out
All passages flushed with hot water and blown through with compressed air



Stuff back from the platers



Con rods all within 1g of each other



Middle main bearings in and cam followers in and lubed up


Case together and all nipped up.
So far so good

Checked end play and barely 1/000 of an inch with a 1.1 shim
Will plan to fit new 1mm shim later today


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[newto912]

End play4.5/1000

I have added a little nick into top of the smaller wedge of the distributor drive gear and filled with daughters nail varnish
I always found this difficult to see when looking down the hole to find TDC on cylinder 1. This should make it easier


Good progress made. Third piece and pulley all on according to the Maestro half way there




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[Timo]

Great work, looks like the rebuild is motoring along!

Looking forward to seeing this progress.

Thanks for sharing

[mycar]

Oh and this is DDk.

If it's not actually your daughters nail varnish.. we understand,

[912uk]

nice..... I must do my one soon... he says 7 years later

[newto912]

I hoped she had yellow or lime green,but had to make do with pink.

Getting my head around piston rings. Have read each piston needs its own bespoke rings, so filing in order. Looked for a ring filer but don't seem to be any in the UK. Plenty in the US. Can't wait for that. So decided to make my own using my dremel about an hour later a small table grinder made and put to good use



All though I didn't remove much from the rings there was lots of tooing and froing between machine and piston
Each piston now has its own bespoke rings
Another job done

One question. Do you leave rings off until
After piston to head clearance has been measured i.e. put them on at the last minute before cylinders go on for the last time?
Thanks



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[neilbardsley]

Re the nick in the distributor drive gear. This is meant to be tapered on one side so you can only insert the distributor one way? I found out that the hard way

[912uk]

yes!! and it's even caught out a very well known builder of 912 engines ...

hey Dan said it wasn't right.

[dcraigmyle]

Excellent post.
Who measured the case for you?
Who did the heads and crank?
Just about to start a rebuild of my 912 engine.

[newto912]

Hi David
PM sent!

[912uk]

i would be interested too as I am looking to get mine put back togeather.. as I had it all blasted ready

[mycar]

Me too.

[newto912]

Back from hols and hood progress at weekend. Few hiccups along the way
Have deleted the oil filter and by passed oil back into the case. Have become a it paranoid about oil pressure and have got a VDO gauge which I will mount somewhere in the cabin
Have a new oil pressure sender from machine 7 which replaces the original oil sender. This has 2 terminals 1 to the warning light the other to the pressure gauge


Hope it all works.

Heads fitted and adjusted the valves not much left on the threads and have checked that oil will flow through to the rockers by taking apart and blowing through with wd40. Thought I would have to machine some shims to bring out the rocker stand

Have an issue with the shasta pump fittings as will not clear the heater boxes. So will have to have a think about that
Does anyone have a piccy of their full flow kit to show what fittings are needed?
There is not enough clearance and I cannot push the heater box up to meet with the exhaust
Was hoping to have it done this weekend, but looks like I will not be able too



Next is the jigsaw of the tin!



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