2.4T engine rebuild - Shock: It actually runs!

[911hillclimber]

There, that feels better!
Carbon on the piston is knackerd rings unless the iron barrels are oval, find out next week.
Not sure about the pump.
Need to look at the pics in Anderson book, it is all there.

The parts bill will now be normal!

[Gary71]

I've checked the book and the pump is the standard one.

In other news: The damage:

From some idiot dropping the fragile magnesium case on the hard tiled floor. Twat.
Luckily the head stud took the worst of it, but the other bent timing chain cover stud will have to come out as well.



Shame as all the studs looked good and I was going to leave them in place!

[sladey]

D'oh!

[911hillclimber]

Mike Bainbridge might have a spare one with patina?
Bloody irritating though.

[Gary71]

Some good news. The cylinders are all still in spec!



So no excuse for new pistons I'm relieved as its a slippery slope of cams, oil cooling and carb tuning. Part of me wanted to go there, my bank really didn't!

I took all the exhaust studs out last night. Only one more needed drilling and helicoiling, but I'm tempted to do all of them.

[myatt1972]

Great news Gary

[jtparr]

C'mon Gary.....pictures needed...

[Gary71]

I've had a week off so just got back to it tonight...

A few hours spent this evening enthusiastically de-coking the heads. With a die grinder.

Not porting as such, I'm not making them bigger, just smoothing out the casting features and blending the valve seats into the ports. Next step is to match the inlet & exhaust manifolds. I'm then getting them blasted to clean the rest of the carbon off and then look at replacing the valve guides and reaming to size.



Once the heads are done it's time to hone the cylinders as one of these is turning up on Monday;

[Gary71]

Well the abrasive bunch of grapes has turned up.



So along with finishing the porting/cleaning another evening of fun awaits learning how to perfect the 30deg cross hatch without making the cylinders 2mm larger...

[Gary71]

First head done.



+0.01hp...but it makes you feel like you tried anyway!

I'm not going for polished as A: Won't make the slightest difference and B: Can't be arsed!

[AndrewSlater]

Gary, I'd be interested to see how you get on with the flex hone as I have also been looking into this.

A couple of questions - did you get one that matches your cylinder diameter? and did you source it in the UK? (They seem cheap in the US but expensive if sourced over here)

Keep up the good work
Andrew

[Gary71]

You are more than welcome to borrow it once I'm done. Are your cylinders iron or aluminium? Not sure what this would do to a Nikasil barrel.

This is a 89mm hone, you chose the nearest larger size.

I bought it in the UK from pacehigh and was £87 delivered. I could probably get them done for not much more, or maybe less! But I like to do stuff myself if possible.

[Gary71]

The cylinder heads are now all finished ready for new valve guides and seat facing.

So onto the cylinders:

A very quick job for a change, probably no more than 10 seconds for each cylinder of actual honing. A couple of very shallow score marks are still visible so I'm happy not to have removed too much material

End result:



Whilst pumping the hone tool in and out you can see the traces left behind in the oil which gives you a good clue if you are getting the crosshatching about right.



Downside is having a big egg wisk covered in wet abrasive grey muck spinning at 1000 rpm seems to have taken the edge off the clean garage.

[AndrewSlater]

They look great Gary.

You can also flex hone the Nikasil cylinders ( mine are 90mm ), I have just been quoted £100 + VAT to have mine done - seems high for 60 seconds work!! Maybe I should do them myself.

Keep the progress updates coming once you have cleaned your garage.

[Gary71]

It is high for 90 seconds work, but it will cost you nearly that for the hone itself as mine is too small for your bores. So maybe not so bad?