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Mike D'Silva

Aircooled Engine Assembly

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Just putting it out there: if you have a 3.0, 3.2 or 3.6 motor that needs a rebuild, feel free to get in touch. I've been rebuilding engines from home for myself and others. Happy to assist those on a budget who cannot afford the big name shops. Whilst I am located in Brisbane, but happy to assist if you are willing to ship your motor, or complete car to me. 

Here is my little website with some photos;

http://www.aircooledporsches.com.au

And you can see some videos of my latest assembly below...

You can email me through the website, or call 0418316203.

 

 

 

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So Mike, for the non-tech members... are you able to describe a few basic things to us:

what exactly does a rebuild do? Replace, repair, clean..?  
And why is it needed?

What are the symptoms that tell you you might need one? 

ive heard about top & bottom end rebuilds... Can you put that it context with the above questions? in particular, how would you know what’s needed?
 

thanks
philbee

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I’m support of Mike. I’ve never met him personally but I recommend him none the less. He’s been around forever on PFA And more recently on the CPA FB page. Always a good contributor in spirit and knowledge. I’ve had many exchanges with Mike recently about EFI set up and tuning related issues and found him to be knowledgeable and with a good fact based logical approach to conversations. If I was more local to Mike I’d have a job for him already. We’re always complaining about Porsche tax and here’s an opportunity to support someone who can work flexibly with you and increased options in a market creates choice. No affiliation but I like what Mike’s doing and think he deserves our support. 

I should add I could ship to Mike but I want to be part of the work (hands dirty) and Melbourne to Brisvegas is just a little too far to work that way. 

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1 hour ago, Philbee said:

So Mike, for the non-tech members... are you able to describe a few basic things to us:

what exactly does a rebuild do? Replace, repair, clean..?  
And why is it needed?

What are the symptoms that tell you you might need one? 

ive heard about top & bottom end rebuilds... Can you put that it context with the above questions? in particular, how would you know what’s needed?
 

thanks
philbee

hi Phil

The requirement for a rebuild varies a lot so it is a little difficult to answer the question definitively. 

I've realised we have a wide spectrum of owners that range from extremely hands on and excessively maintained, to those that own the cars and don't really know much mechanically and tend to treat their car like an old Toyota; never service and just keep driving. So the cars tend to be in varying states of condition. But the common issues that would require some form of rebuild would be 

- broken headstuds

- burnt valve seats

- worn valve seals

- excessive oil consumption

- excessive oil burning

- oil leaks

- low oil pressure

 

For me, rebuilding an engine is a total rebuild; split cases, check all tolerances, new main and rod bearings, rod sizing checked, wrist pin bushings replaced etc.

Usually a top end only, is just having the heads refurbished, check cylinders and pistons for being within spec, and replacing rings. Might replace headstuds too. (if you don't have proof of headstuds being replaced at some time, then always replace them)  But a 'top end' only is not always a wise choice. and here are a couple of examples below.

Recently, I completed just a 'top end' rebuild for a 3.2 at the request of the owner, due to 3 broken headstuds. Now, my preference was to split the case and inspect but he assured me that oil pressure was adequate, and that he actually had receipts for a FULL rebuild by a well known shop only approx 20kms ago (but it was about 15 years or so). Why did the headstuds break? Well, when they rebuilt it back then, they did not replace the dilavar exhaust studs.. maybe it wasn't the done thing back then.. I removed all studs and replaced with steel.

Upon dissassembly, we found 3 cylinders to have excessive scoring and the nikasil plating had been compromised, so all cylinders were replated and honed. Yes, the cost went up, but now, the owner has a car with refurbished heads, good compression, and frankly a bit of a rocket. I'm really happy with how that car performs. 

 

Another engine was targeted for just a 'top end' rebuild. This engine was very leaky... top and bottom.. so the owner just wanted the top end disassembled, checked and then reassembled Upon disassembly, I found 1 broken headstud that the owner was not aware of, and I saw enough evidence to persuade the owner to let me split the case. He had no history for any rebuild work done before to that engine. When I split the case, 1 of the crankshaft bearing shells fell out and was worn down to the copper.. it was trashed. Likely in a previous owners care, back when these cars were not cared for. We were lucky in that the crankshaft needed just a polish and was still straight with no cracks etc. The case however, needed a LOT of fettling to bring the bores back to within spec. This allowed the used of stock size bearings (not the $2500 oversized ones from porsche) and the engine was rebuilt back to stock. We also found the rockers and cams to have mild pitting and 1 of the cylinders to have some delamination of the nikasil.

I always keep owners well informed of where I am in the process, and if something crops up that wasn't expected, then I am straight on the phone and send photos and /or video. When I rebuild fully, I have all the parts ultrasonically cleaned. Depending on budget, my preference is to have cylinders, heads and cam towers vapour blasted and for rocker covers and timing chain covers to be powder coated. Engine tins are sandblasted and powder coated too.

So basically, you end up with a brand new looking and performing engine. Process takes a few weeks to complete and I only like to work on one engine at a time. 

Hope this information helps. 

 

 

 

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Great service to offer and I take my hat off to you for doing so ... it's always good to see someone giving back to "the community" to offer what many can't achieve ... 

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5 hours ago, Pork Chops said:

I’m support of Mike. I’ve never met him personally but I recommend him none the less. He’s been around forever on PFA And more recently on the CPA FB page. Always a good contributor in spirit and knowledge. I’ve had many exchanges with Mike recently about EFI set up and tuning related issues and found him to be knowledgeable and with a good fact based logical approach to conversations. If I was more local to Mike I’d have a job for him already. We’re always complaining about Porsche tax and here’s an opportunity to support someone who can work flexibly with you and increased options in a market creates choice. No affiliation but I like what Mike’s doing and think he deserves our support. 

I should add I could ship to Mike but I want to be part of the work (hands dirty) and Melbourne to Brisvegas is just a little too far to work that way. 

Thanks Nick, really appreciate the comments.

 

4 minutes ago, Dreamr said:

Great service to offer and I take my hat off to you for doing so ... it's always good to see someone giving back to "the community" to offer what many can't achieve ... 

thankyou :)

 

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Mike lives just over the hill from me and checking out 'whats on' on occasion is pretty cool - I'd take beer, but that might be detrimental.!

Keep up the great work.!

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1 hour ago, AdRock said:

Once I start mine up after my own rebuild and the pistons hit the valves, I'll send it to you to redo and do it properly.   ;)

 

Your best bet is to leave them out when doing the rebuild, that way there's no chance of valve hitting piston.

I'm not even an engineer and I know to do this.

 

You're welcome.

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On 20/02/2020 at 11:58, jakroo said:

Your best bet is to leave them out when doing the rebuild, that way there's no chance of valve hitting piston.

I'm not even an engineer and I know to do this.

 

You're welcome.

I think (hope) he was joking!

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