MFX Posted 29March, 2017 Report Share Posted 29March, 2017 Hey guys,I thought it would be better to start a new thread specifically for the engine rebuild. As many of you may know I have sent my engine parts to LA, to Performance Development. They have been busy cleaning up the parts and seeing what we have to start with. The current prognosis is not great. The half-witted apes who "rebuilt" (and I use that term very loosely) the engine previously have butchered it. Essentially the engine obviously had pulled head studs, like every other 2.7, but it was the way they went about "fixing" them that was the problem. It looks like a the original stud holes in the case were drilled out by a blind man using a potato. These have been overdrilled in a few cases where it has cracked the case. They then proceeded to half insert some helicoils. From there it looks like they went down to the local hardware store to find new case bolts. Obviously, because the holes in the case weren't square, they couldn't get the head bolts to line up and screw in. No problems, they just re drilled oblong holes in the heads, and cylinders to line up.Now I know what you are thinking. The whole engine is basically a throw away. Well in many cases it would be, but it doesn't have to be. What if the engine was matching numbers to a rare car (or to be honest matching numbers to any aircooled 911 these days). Well thankfully that is what Performance Developments do. So although my engine is not matching numbers, they are willing to look after me to save me the money of buying something else unkown, and they can demonstrate what level can actually be repaired and to a standard that will last.So that is where we are at for now. The mind still boggles at how stupid some people can be. Link to comment Share on other sites More sharing options...
firstone Posted 29March, 2017 Report Share Posted 29March, 2017 Geez, you wouldn't do that to a chinese 2 stroke.You're a can do bloke that's for sure. ? Link to comment Share on other sites More sharing options...
LeeM Posted 29March, 2017 Report Share Posted 29March, 2017 Sat here in utter disbelief at that last pic! Even my ex mechanic missus looked at me with WTF? Unbelievable The missus just asked to look at the pics again. And I quote... 'Jeff should track down the dickheads that butchered that engine and shoot them! How close to the cylinder wall is the hole!!! Jeeeebus!' 'I don't care if its a Porsche or a Mini, you just don't do work (if thats what that is called) like that! What a bunch of morons'...unquote. She's still shaking her head about it The missus ain't happy Jeff! Link to comment Share on other sites More sharing options...
MFX Posted 29March, 2017 Author Report Share Posted 29March, 2017 Sat here in utter disbelief at that last pic! Even my ex mechanic missus looked at me with WTF? Unbelievable The missus just asked to look at the pics again. And I quote... 'Jeff should track down the dickheads that butchered that engine and shoot them! How close to the cylinder wall is the hole!!! Jeeeebus!' 'I don't care if its a Porsche or a Mini, you just don't do work (if thats what that is called) like that! What a bunch of morons'...unquote. She's still shaking her head about it The missus ain't happy Jeff!I know, even the guys with the engine in the US have been building engines for over 30 years, have never seen that level of butchery! I was worried when I saw one of the 'head studs' I removed from the engine, which was much thicker than the others and had about 10 washers on it.... Link to comment Share on other sites More sharing options...
Mike D'Silva Posted 29March, 2017 Report Share Posted 29March, 2017 Awesome.. this might just become the "definitive 2.7 CIS 911 engine build worldwide"!!There is lots of talk on other forums about rebuilds, but so far, this is the only one with some real content. I am very eager to learn what they can do to recondition and repair the cases.Those heads are awesome... sounds like your case had "porcupine" head stud syndrome Link to comment Share on other sites More sharing options...
MFX Posted 29March, 2017 Author Report Share Posted 29March, 2017 Awesome.. this might just become the "definitive 2.7 CIS 911 engine build worldwide"!!There is lots of talk on other forums about rebuilds, but so far, this is the only one with some real content. I am very eager to learn what they can do to recondition and repair the cases.Those heads are awesome... sounds like your case had "porcupine" head stud syndrome Except for the CIS bit . I plan on going with some form of EFI, just not sure what way I am going yet. Link to comment Share on other sites More sharing options...
LeeM Posted 29March, 2017 Report Share Posted 29March, 2017 I know, even the guys with the engine in the US have been building engines for over 30 years, have never seen that level of butchery! I was worried when I saw one of the 'head studs' I removed from the engine, which was much thicker than the others and had about 10 washers on it.... Haha. Paula (the missus) just said 'Wow, that's very bad!' (actual wording changed due to the VERY fruity language and name calling being used!) Link to comment Share on other sites More sharing options...
Pauly Posted 29March, 2017 Report Share Posted 29March, 2017 I know how you feel about this sort of stuff. I've seen some knob heads do some stupid shit to engines before. Good luck with it. engine building is fun! Link to comment Share on other sites More sharing options...
Raven Posted 29March, 2017 Report Share Posted 29March, 2017 Yep I feel your pain Jeff ,,,like Lee said the first image had me shaking my head the other images have me just dumbfounded ......... Link to comment Share on other sites More sharing options...
Timm Posted 29March, 2017 Report Share Posted 29March, 2017 Good lord...some people shouldn't be let near cars, let alone engines Link to comment Share on other sites More sharing options...
Raven Posted 29March, 2017 Report Share Posted 29March, 2017 Well there is a 3.0 SC case on ebay ,,not to far from you ...............? http://www.ebay.com.au/itm/Porsche-911-SC-engine-cases-excellent-cond-930-RS-turbo-RUF-MFI-UPDATED-FREIGHT-/302263007611?hash=item466047797b:g:~qgAAOSwuxFYw6j- Link to comment Share on other sites More sharing options...
ruby82sc Posted 29March, 2017 Report Share Posted 29March, 2017 As a local in the throws of a 2.7 rebuild (that I thought had issues) and being a burnt out old earthmoving diesel fitter I am lost for words........... Link to comment Share on other sites More sharing options...
MFX Posted 29March, 2017 Author Report Share Posted 29March, 2017 The guys at PD are repairing it now, so it should be interesting following the progress. Link to comment Share on other sites More sharing options...
P-Kay Posted 29March, 2017 Report Share Posted 29March, 2017 Easy repair for a quality machine shop. Weld and retap, heads are no biggie, but the cylinders.....at least they are sleeved!!! Link to comment Share on other sites More sharing options...
81SC Posted 29March, 2017 Report Share Posted 29March, 2017 Those guys definitely had the blue & white aprons on when they rebuilt that engine.A case of not understanding their ambitions & capabilities. Just because you think you can do something, doesn't mean you have the capabilities. Link to comment Share on other sites More sharing options...
Mike D'Silva Posted 29March, 2017 Report Share Posted 29March, 2017 Who is doing the assembly? Link to comment Share on other sites More sharing options...
michel Posted 30March, 2017 Report Share Posted 30March, 2017 Who is doing the assembly?mrs Jeff? Link to comment Share on other sites More sharing options...
MFX Posted 30March, 2017 Author Report Share Posted 30March, 2017 Who is doing the assembly?You know I am dying to do it . You can't have all the fun Link to comment Share on other sites More sharing options...
Cheshire Cat Posted 30March, 2017 Report Share Posted 30March, 2017 You know I am dying to do it . You can't have all the fun why not?:)))) Link to comment Share on other sites More sharing options...
Gsaps Posted 30March, 2017 Report Share Posted 30March, 2017 I've been watching your YouTube channel and progress Jeff, you're doing an amazing job and have an enviable skill set i was wondering why you sent the engine all the way to the US, Is there nowhere in Australia that can do this sort of work looking forward to the next episode edit: just seen the thread on the shipping explaining your reasons for the US route Link to comment Share on other sites More sharing options...
MFX Posted 31March, 2017 Author Report Share Posted 31March, 2017 I've been watching your YouTube channel and progress Jeff, you're doing an amazing job and have an enviable skill set i was wondering why you sent the engine all the way to the US, Is there nowhere in Australia that can do this sort of work looking forward to the next episode edit: just seen the thread on the shipping explaining your reasons for the US route It is a good thing I sent it to them now, seeing the level of damage, they are the ones to fix it.Have a look at this 962 engine they resurrected after a fire. The thing was toast, and they brought it back from the dead.http://performancedevelopments.com/porsche-962c-resurrection/ Link to comment Share on other sites More sharing options...
MFX Posted 23April, 2017 Author Report Share Posted 23April, 2017 A bit of an update on what is happening with my butchered engine parts. Neil at Performance Developments has been working away repairing the heads at the moment. They repaired the worst head first. "..The insert is threaded into the head, so it cannot move sideways when the head gets hot. It couldn’t move up or down as the cylinder would stop it on one side and the head washer the other.."So it is looking a lot better than it did before. Link to comment Share on other sites More sharing options...
rafikdous Posted 10May, 2017 Report Share Posted 10May, 2017 Kudos for your perseverance Link to comment Share on other sites More sharing options...
MFX Posted 13May, 2017 Author Report Share Posted 13May, 2017 Just got back from LA this morning, and as of yesterday, we had repaired the worst of the holes in the case. The biggest issue is that the hole they drilled was so far from where it was supposed to be. But now we have repaired this one (the worst one) the rest will be a doddle. Link to comment Share on other sites More sharing options...
Spectre Posted 13May, 2017 Report Share Posted 13May, 2017 Great episode Jeff, amazing stuff.Mrs Jeff out shopping? Link to comment Share on other sites More sharing options...
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