Coastr Posted 22January, 2015 Report Share Posted 22January, 2015 Any updates? Still no progress? Link to comment Share on other sites More sharing options...
Dusty Posted 22January, 2015 Author Report Share Posted 22January, 2015 I'm not familiar with Don Munro, Porschie, but the name sounds familiar? There's been progress with the stud otherwise and what's left of it has finally been removed. Here is what the A(*&^ W$#@ (#*@b of a stud looks like after today: Can't say I'm not pleased. Traditional methods of stud removal were not sufficient so EDM was required. The only saving grace was that the chaps at the local machine shop were able to plug up many of the crankcase openings and run the coolant direct/without immersing, so its internals remain free of debris. I'm still assessing the crankcase but from from what I've seen so far, the case is very clean and won't need to be split. This was an image of the process: That little blue spark is pumping out over 10,000 watts, good enough to begin a BBQ or two Other items attended to while this was taking place include replacing all the CIS rubber boots and injector sleeves/o-rings: Yet to install the new blow-off valve as I'm choosing to focus on the long block so my efforts will be focused with what needs doing there for the moment. Planning to spend some serious time on it tomorrow so hopefully will have some more updates shortly. Link to comment Share on other sites More sharing options...
firstone Posted 22January, 2015 Report Share Posted 22January, 2015 Great news. Well done, you must be relieved. Link to comment Share on other sites More sharing options...
Coastr Posted 22January, 2015 Report Share Posted 22January, 2015 Awesome! Which shop did it for you? Link to comment Share on other sites More sharing options...
Dusty Posted 23January, 2015 Author Report Share Posted 23January, 2015 Very relieved thanks firstone, still a bit nervous that something might have entered the case but I searched it high and low this morning and couldn't see any debris. Will probably perform frequent oil changes over the next few months to be safe. Coastr, it was a small machine shop in Brendale that did it for me, basically as a favour as they normally work on mining and other specialised gear. I've asked him if he's happy for me to disclose his details here and am awaiting a response. Will report when I can. Got a bit of work done today, new chain ramps installed, all head studs in and installed 4 out of the 6 cylinders. Tomorrow I'll install the last 2 cylinders then tackle the heads/cam housing but I've got a few doubts here. They're in one piece which is fine for re-install however I'm concerned the electrosonic cleaning might have weakened/washed away the loctite gasket between the heads and cam housings... I'm not sure there's a way to check without pulling it all down (remove rockers, cams, nuts then split) so I think I'll just have to do it. Regretting the electrosonic cleaning now but I dont think I would've got them anywhere near as clean. Besides that stuff-up, I also thought my gasket kit contained the oil breather gasket and thermostat 0-ring but sadly I'm mistaken. Will have to source them locally if anyone can recommend a supplier? Link to comment Share on other sites More sharing options...
Coastr Posted 23January, 2015 Report Share Posted 23January, 2015 Get onto justjames at autohaus Hamilton. If it's in stock he'll get it to you quick. Link to comment Share on other sites More sharing options...
Caledonian Posted 23January, 2015 Report Share Posted 23January, 2015 I have a spare gasket but can't help with the o-ring, possibly a bearing/hydraulic shop might be match one for you depending on how quickly you need it. Link to comment Share on other sites More sharing options...
SimonR Posted 24January, 2015 Report Share Posted 24January, 2015 Just checked my latest box of goodies -- I've got a spare gasket as well... I also ordered two thermostat o-rings but they were out of stock. Delivery expected at some point next week. If you're happy to wait, you're welcome to it. If you're in a hurry try just James or porsche centre Brisbane spare parts should be open this morning. They should have one in stock. Link to comment Share on other sites More sharing options...
jnr356 Posted 24January, 2015 Report Share Posted 24January, 2015 there are 2 engine gasket kits,upper and lower lower kit contains all gaskets for crankcase upper does the rest Link to comment Share on other sites More sharing options...
Dusty Posted 24January, 2015 Author Report Share Posted 24January, 2015 Thanks guys, that's fantastic! I'm able to progress without them at present so I'll give James a call on Monday and see if he has any in stock. If not, I'll take you up on the offer if I'm able and replenish asap. Made some more ground today despite family activities taking up half the day. Removed the rockers, installed the heads and cam housings - had one cock up where I forgot to install the cylinder tinware on one bank but it was quickly rectified... It's beginning to look like an engine once more. Glad I took the rockers off as I'm now convinced two of the oil leaks were coming from here after looking at a few of the tear-down photos. They were severely under torque'd so hopefully by re-installing them correctly, another fault will be cured. Aiming to complete the long block before the end of the long weekend as I'm back to work Tuesday... Will feel better once the dreaded cams are timed but it's already satisfying knowing the cylinders are bolted on with four head studs a piece! Link to comment Share on other sites More sharing options...
SimonR Posted 25January, 2015 Report Share Posted 25January, 2015 Great progress dusty! Link to comment Share on other sites More sharing options...
Dusty Posted 26January, 2015 Author Report Share Posted 26January, 2015 Thanks Guys, on the down hill run now. Had a few welcomed interruptions over the weekend so didn't get to my goal of a sealed up long block but I am mostly there. Cams are now timed (perfectly after 3 attempts - difficult at first but makes sense after you go along), chain tensioners, idler arms installed and one cam cover sealed. Still have a bit to do but it's mainly installing the accessories which I should manage over the coming week, ready for re-entry over the weekend. The only problem I've encountered is two of the rockers are seizing when I torque them up to the required amount. I've only installed the 1 and 4 intake and exhaust rockers so far and two of them will only take about 10nm before their movement on the shaft is impeded, I'm aiming for 17.5nm as per Dempsey's book but I know of others going higher... Anything I'm missing? Link to comment Share on other sites More sharing options...
Caledonian Posted 26January, 2015 Report Share Posted 26January, 2015 Is the position of the shaft correct, i recall reading something about they don't sit central but slightly off… might be wrong there can be several versions of the truth when it comes to internet facts…… Link to comment Share on other sites More sharing options...
Dusty Posted 26January, 2015 Author Report Share Posted 26January, 2015 Well spotted - I just checked and I think you're right. I'd read about the off-centre rockers maybe a dozen times and still didn't put it into practice! Good thing it's only 2 rockers I need to re-install install of the all 12. Thanks mate! That's two I owe you now! Link to comment Share on other sites More sharing options...
Dusty Posted 28January, 2015 Author Report Share Posted 28January, 2015 Well James from Autohaus came through for me in a big way. He deciphered my order yesterday and had it to me today, unbelievable and cheap. Wont waste time ordering from OS in future! Getting onto the home straight now, the accessories are quickly being installed and my job sheet is shortening. Last night I added the remaining rockers, set the valve clearances and cleaned up the last of the cam/valve covers. Tonight I was able to install the cam oil lines, cam covers, valve covers and oil breather gaskets/thermostat. Over the coming nights I'll try to install the heat exchangers/zorst, oil cooler, fan, engine shroud/tin, wiring loom and the CIS so that by Saturday, I'll be right for the long awaited re-entry and start up. Cant wait to drive it but also looking forward to having a tidy garage back again! Link to comment Share on other sites More sharing options...
Caledonian Posted 28January, 2015 Report Share Posted 28January, 2015 Looking good! Link to comment Share on other sites More sharing options...
Coastr Posted 28January, 2015 Report Share Posted 28January, 2015 Looks great. You can look forward to bending your head under the car every time you stop looking for oil drips! Link to comment Share on other sites More sharing options...
Rocket Posted 29January, 2015 Report Share Posted 29January, 2015 Nice work!! Link to comment Share on other sites More sharing options...
Dusty Posted 29January, 2015 Author Report Share Posted 29January, 2015 Coastr I think initially, I'll have my whole head out the window listening for explosions. It'll be a load off when I'm comfortable enough just to look for oil leaks! No, with the exception of the stuck head stud, it's been a largely uneventful re-build which are the best type. Will still be a nervous first time start... As they all are! Link to comment Share on other sites More sharing options...
Coastr Posted 29January, 2015 Report Share Posted 29January, 2015 I'm away this weekend so I can't come and listen. If you're still going on sunday afternoon maybe I can come hold the fire extinguisher. Link to comment Share on other sites More sharing options...
oldslappy Posted 29January, 2015 Report Share Posted 29January, 2015 Hi Dusty, Great post. Brings back memories of when I rebuilt mine. I still recall my heart pounding out of my chest as i hit the key for the first time, thinking good god I hope that cam timing is correct. Anxiety soon turned to excitement as oil psi built & eventually it fired up on all cylinders. Link to comment Share on other sites More sharing options...
Dusty Posted 30January, 2015 Author Report Share Posted 30January, 2015 Here's hoping that I'll have the same oil pressure build as you did oldslappy! Getting close now so hopefully with some luck tomorrow will be the launch day but I'm determined not to rush so there's nothing lost if it's Sunday. At least then fireman Coastr can give some assistance too. Only minor details remain as the CIS is now installed and just needs to be secured as well as re-connecting the majority of the wiring and bolting down the shroud/tinware. Then it'll be a job to get it off the stand, onto the atv jack, re-connected the the trans and then in she goes. I'll install the exhaust system after the engine is back in as I'll need the additional clearance to get the motor back under the bumper (it's also the same way the engine came out). I'm now content with the way the engine looks, it's now just a matter of seeing how (...if) it goes! Link to comment Share on other sites More sharing options...
Caledonian Posted 30January, 2015 Report Share Posted 30January, 2015 Youv'e done a great job with the fan Dusty, very impressed. Meant to ask, did you clean out your oil tank? As this is what I found with mine.. Link to comment Share on other sites More sharing options...
Dusty Posted 31January, 2015 Author Report Share Posted 31January, 2015 I haven't touched the oil tank Caledonian... I saw your post and was committed a few weeks ago but got pre-occupied by the disagreeable head stud so didn't remove it. Might do so at the next oil change which will be very soon, agree it wont be as simple though. Didn't get the engine installed today as moving the fully loaded engine off the stand took longer than expected. As did installing the tinware etc but a huge thanks to Paul Carrerra who dropped around this arvo and basically man-handle the motor off the stand as well as re-installing the clutch, transmission to engine and fan pulley. We're now sorted for re-ignition tomorrow morning but here's the state of play at the moment. Not much change here Link to comment Share on other sites More sharing options...
SteveF Posted 31January, 2015 Report Share Posted 31January, 2015 Looks fantastic Dusty. Good luck for tomorrow. Link to comment Share on other sites More sharing options...
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