It started with a pop

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AndrewSlater
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Re: It started with a pop

Post by AndrewSlater »

I've been slowly removing material from my cylinder heads so that everything matches my 'worst case' largest chamber.
The largest chamber consistently measured at 62.8cc, whereas the other head had two nicely matched chambers of 61.4cc.

It's taken a number of days to slowly slowly remove some material, clean up the heads, dry them out and remeasure several times.
I was using a stopwatch to limit myself to only removing 90 seconds of material at a time with the Dremel, but even this doesn't guarantee how much you will remove.
I've had times where 90 seconds would remove up to 0.2cc of material and other times it didn't even register as a 0.1cc change.

Well I can see where the times ( and costs ) accumulate for a good engine rebuild, I must have spent 10 hours or more trying to match the heads.

Eventually I had two heads with each chamber volume matched to 62.8cc +/- 0.1cc ( best I can measure ).

To celebrate I decided to change the exhaust studs to a new set.

The first 7 swapped without the drama, but the last one wouldn't budge.
I got out my trusty Sealey Pro stud extractors and they stripped every last thread off the stud - bugger!
The Sealey amateur ones must really be cr*p!

Clearly panic set in at this stage as I started to consider whether I had trashed my newly size head.
I should have left the studs they didn't look that bad - but it was unusable.

So after much wrangling, cursing and different tools and ideas I eventually got it out using my vice.
Image

Phew!!


Image
The finished heads.

Next step- refitting the third piece.
1966 Porsche 912 Slate Grey, red interior - first owner owned for 41 years
1974 Porsche 911 2.7 (The Manhattan project) viewtopic.php?f=28&t=51455
1973 VW 914 1.7 Olympic Blue - ( gone to a good home )
Nine One One
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Re: It started with a pop

Post by Nine One One »

Andrew,
Next time for stuck studs, try this stuff?

https://www.screwfix.com/p/arctic-produ ... 00ml/83415
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AndrewSlater
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Re: It started with a pop

Post by AndrewSlater »

Thanks for the suggestion.

I did actually use an equivalent shock spray ( I used Quinton Hazell Freeze and release spray ) after extensively heating the head with my hot air gun, before using the stud extractor - so was surprised it put up such a fight. When it did come out it was a very clean thread so unsure what was holding it in so well.

Hopefully that's the last hurdle.
1966 Porsche 912 Slate Grey, red interior - first owner owned for 41 years
1974 Porsche 911 2.7 (The Manhattan project) viewtopic.php?f=28&t=51455
1973 VW 914 1.7 Olympic Blue - ( gone to a good home )
neilbardsley
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Re: It started with a pop

Post by neilbardsley »

I was going to say with the good work you are putting in there should be no next time!
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Re: It started with a pop

Post by AndrewSlater »

I'm with Neil - I don't think it will be me doing the next engine rebuild on this car! :wink:
1966 Porsche 912 Slate Grey, red interior - first owner owned for 41 years
1974 Porsche 911 2.7 (The Manhattan project) viewtopic.php?f=28&t=51455
1973 VW 914 1.7 Olympic Blue - ( gone to a good home )
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Re: It started with a pop

Post by AndrewSlater »

So here is a close up photo of the modified 3rd piece with the new oil tube fitted- as promised.

Image[/url]

The next job was to install the third piece using the Maestro's technique for pre-fitting the distributor drive.
I double and treble checked I had all the o-rings fitted - didn't want to miss one.

Four of the mounting nuts are for the engine carrier so decided to fit these nuts alone in addition to the other seven, in order to torque down the third piece to allow the sealant to go off.

With the third piece fitted the crankshaft still turns nicely - so far so good.

Image

Can you tell I'm paranoid of dropping something into the case!
1966 Porsche 912 Slate Grey, red interior - first owner owned for 41 years
1974 Porsche 911 2.7 (The Manhattan project) viewtopic.php?f=28&t=51455
1973 VW 914 1.7 Olympic Blue - ( gone to a good home )
robs912
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Re: It started with a pop

Post by robs912 »

Hi Andrew
Looks like your are making good progress!
When I fitted the premat oil pump cover I found that I had to remove the two locating pins to get the pump gears to turn freely. I'm not sure this is mentioned in the instructions but I'd read it somewhere (probably on bbs 912).
Cheers
Rob
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Re: It started with a pop

Post by AndrewSlater »

Having been slowly making more progress.

I fitted the oil pump and the precision matters full flow kit.
The oil pump gears went in without any trouble, and the crank still turned smoothly so hopefully no problems there Rob.
I haven't fitted the stone cover plate yet as I am considering fitting a heatsink to the oil filter to help with oil cooling.
I bought a Bosch oil filter as I think it looks a bit less out of place than the Mobil 1 filter supplied.

I then moved onto fitting the oil cooler, filling the internal passageways with oil to help with first startup.

Big thanks to Andrew and Neil for offering to loan their torque converters.
I decided to try the flywheel torque multiplier - thanks Neil.

This allowed me to semi torque the old gland nut up with the new shim I had bought.
Image
I previously had about 0.22mm endplay or so, so I had gone from a 0.95mm shim to a 1.05mm one.

With the new bearings fitted, new shim, old gland nut and old crankshaft gasket I was getting just under 0.12mm play, which stacked up with the change of shim..
I was a little worried that with the new gasket and full torque I might get a bit further away from the goal of 0.14mm, so I decided to sand down my shim 0.02mm or so.

Image

Image
This time I got 0.14mm bang on so decided to fit the seal and fix the flywheel on for good with the new gland nut.
The torque multiplier really makes the job of putting the gland nut on really easy - so much so you start to doubt it is actually torqued correctly.
The gearing ratio is actually 130 ( flywheel ) to 14 ( tool gear ) which is 9.28:1. The tool claims a 9:1 multiply so that's the figure I went with.
For 425ft/lb you put 47ft/lb in.

With the flywheel on for good, I tentatively measured the endplay again and it is definitely 0.14mm so bang on the Maestros recommendation - great!
1966 Porsche 912 Slate Grey, red interior - first owner owned for 41 years
1974 Porsche 911 2.7 (The Manhattan project) viewtopic.php?f=28&t=51455
1973 VW 914 1.7 Olympic Blue - ( gone to a good home )
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Re: It started with a pop

Post by AndrewSlater »

In other news, I fitted the pulley end of the engine, oil slinger, pulley seal and pulley.

I also fitted the distributor, sump plate and oil relief valves.

It was then time to fit the pistons, cylinders and heads.
I used new cylinder head nuts and new oil tubes so plenty of shiny bits.

I followed the Meastro's recommendations for torqueing the heads up together, incrementing each side at a time and a final three checks at the end.
I left it overnight for it to settle and then did a final torque again - a few of the nuts moved a smidgeon but nothing worth noting.

The engine still turns although there is quite a bit more force to overcome with the rings in the bores.

Image

Starting to look like an engine.
1966 Porsche 912 Slate Grey, red interior - first owner owned for 41 years
1974 Porsche 911 2.7 (The Manhattan project) viewtopic.php?f=28&t=51455
1973 VW 914 1.7 Olympic Blue - ( gone to a good home )
neilbardsley
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Re: It started with a pop

Post by neilbardsley »

Good progress. I've always thought that, even with the shield, moving having an external oil filter near the exhaust was the weakest part of the design

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Re: It started with a pop

Post by Kneeslider »

Hi Andrew. What did you do when fitting the crank pulley seal? I have seen a lot written about using the special Porsche tool to seat the seal properly in the 3rd piece.

The last time I did it, I just tapped the seal in place, and all seemed well, however on stripping the engine 6k miles later, I found that I had a leak from this area. Part of the problem could have been a wear ridge on my pulley, which I plan to fit a speedy sleeve to, but it also made me wonder about how critical the fit of the seal is. Surely it must be possible to fit the seal without the special tool and still have a good result.
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AndrewSlater
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Re: It started with a pop

Post by AndrewSlater »

Neil - a lot of people call the shield a stone shield to protect the oil filter from being punctured by stones, however to my mind it is as much a heatshield to keep the exhaust heat off the filter. It is angled more towards the exhaust than the ground, which suggests the latter. I have bought an aftermarket heat sink that I will see if I can manipulate to fit with the shield. I do have some gold leaf - maybe I should gold leaf the shield for maximum heat reflection - a la McLaren.

As for the seals, I bought the CSP crankshaft seal fitter special tool as I was told a standard type 1 would work. It is a two stage tool whereby you fit the seal on one side and then changeover for the second step.
I have to say the two steps make no sense on a 616 case, so in effect I used it as a big washer with the gland nut. The seal at this end went in pretty well but not sure the tool helped in any useful way.
I had a choice of a Victor Reinz seal or an Elring one, so flipped a coin and went for the latter.

I didn't buy the special tool for the pulley end as they are pretty expensive. I tapped it in with a socket I have that fits well.
I did spend quite some time to polish my pulley so that it had an ultra smooth surface to spin against, and lubricated it all before fitting - so time will tell.
I fit an Elring one at this end straight out of the bottom end gasket set.

I even painted the edge of my pulley black, and painted the timing mark yellow to give the best contrast when timing the car.
The pulley also got a new oil spinner washer ( my old one was very tired looking ) and a new woodruff key.
Plenty of new parts you really can't see but I know they are there.
1966 Porsche 912 Slate Grey, red interior - first owner owned for 41 years
1974 Porsche 911 2.7 (The Manhattan project) viewtopic.php?f=28&t=51455
1973 VW 914 1.7 Olympic Blue - ( gone to a good home )
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Re: It started with a pop

Post by AndrewSlater »

The next step was to fit the valve train.

Now I had purchased four new valve adjusters screws which I put on cylinders 3 and 4. I chose the best 4 from my remaining 7 for cylinders 1 and 2.
They all got new adjusting nuts all round.

Image

I've currently got all the inlet and outlet valves set at 8 thou ( 0.2mm ) as recommended by the Maestro for the first 50 mile engine run in.
I'm wondering whether I should drop the inlets to something closer to 6 thou for first run in - still undecided.
1966 Porsche 912 Slate Grey, red interior - first owner owned for 41 years
1974 Porsche 911 2.7 (The Manhattan project) viewtopic.php?f=28&t=51455
1973 VW 914 1.7 Olympic Blue - ( gone to a good home )
robs912
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Re: It started with a pop

Post by robs912 »

Looks like you will soon be ready to fire it up!
The oil temp in mine runs much cooler since fitting the pre mat filter so I think the heat shield does its job. Also I reckon the extra amount of oil must help.
Andrew did you cut the second lip off the flywheel seal? As recommended by others. Andrew (newto912) advised me to do this and no leaks so far. Fingers crossed.
Cheers
Rob.
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Re: It started with a pop

Post by AndrewSlater »

With regards to the oil temperature, I spotted a 'cheap' new aluminium oil cooler on eBay so have ordered it.
The oil cooler on the car is the original 1966 steel one so possibly past its best. The new one should help with cooling but also remove some of the weight hanging off the case. I'd already fitted the old one, but can easily swap it over.

As for the flywheel seal, the one that came off didn't seem to have a second lip nor could I see any modifications.
The new Elring one looked the same (single lipped) so I simply fit it.

Thanks for pointing this out - though really that's just one more thing for me to worry about at night :roll:
When I stripped the engine down everything seemed simple, now that I'm putting it back together I'm sensing that there are plenty of things that I could really mess up. ;)
1966 Porsche 912 Slate Grey, red interior - first owner owned for 41 years
1974 Porsche 911 2.7 (The Manhattan project) viewtopic.php?f=28&t=51455
1973 VW 914 1.7 Olympic Blue - ( gone to a good home )
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