gregmarshall
New member
I'm toying with the idea of rebuilding my own engine so would like to ask if anyone can share their experience/knowledge?
DIY Rebuild - How hard can it be?
- Thread starter gregmarshall
- Start date
Steve Brookes
Moderator
Mr Moots and Ian Gray, to name but two, could probably give you some pointers.
Have a look at my thread in my signature as its covers the rebuild I did and made it into Total 911 magazine as well....and the car is still working very nicely thank you ;-)
Depending on your historical skills , the 964 engine is an "engineers engine" not a cheap as chips Ford Pinto, so everything is made and needs to be assembled to finer tolerances and a few special tools will be needed so you can't throw it together. A pro will take approx 70-80hrs to remove, rebuild and refit an 964 engine. It took me about a 100hrs and I have rebuilt many engines in the past and a lot of time is undoing broken studs etc etc ...took me a long days work to get all the head studs out of crankcases!!.
With all the adjustment you can make and also you have to adjust too, you can see the engine come from the racing scene.
Some sound advise I received once ..it will problem be the most expensive engine you will work on and parts are not cheap !!
And yes I would do it again but that's me ;-)
Depending on your historical skills , the 964 engine is an "engineers engine" not a cheap as chips Ford Pinto, so everything is made and needs to be assembled to finer tolerances and a few special tools will be needed so you can't throw it together. A pro will take approx 70-80hrs to remove, rebuild and refit an 964 engine. It took me about a 100hrs and I have rebuilt many engines in the past and a lot of time is undoing broken studs etc etc ...took me a long days work to get all the head studs out of crankcases!!.
With all the adjustment you can make and also you have to adjust too, you can see the engine come from the racing scene.
Some sound advise I received once ..it will problem be the most expensive engine you will work on and parts are not cheap !!
And yes I would do it again but that's me ;-)
After I broke off a stud changing my oil pressure sender, I can imagine how hard a complete engine strip down could be and all the associated pitfalls. I eventually called out an expert who fixed it, but not after a few nights of swearing.
On the flip side, there would be no shortage of people available to give you a hand [
]
On the flip side, there would be no shortage of people available to give you a hand [
]
ORIGINAL: C2dweller
After I broke off a stud changing my oil pressure sender, I can imagine how hard a complete engine strip down could and all the associated pitfalls. I eventually called out an expert who fixed it, but not after a few nights of swearing.
On the flip side, there would be no shortage of people available to give you a hand [
You should have got in touch Lee. I would have popped round with a boot full of tools and moral support.
Depends on what you have planned and what previous experience you have. Probably not recommended if you have little engine rebuild experience. But if you are reasonably skilled and prepaired to spend some time researching the subject then they are straight forward to work on. But require (as all good rebuilds do) care , careful measurement and a degree of skill to put back together well. I came from a background of aircooled VW's which I think helped in understanding some of the oddities of a flat air cooled design.
There are quite a few special tools which you will have to either purchase or make, ok if you plan to purchase but another skill set to add if you don't. In particular a decent engine stand and yoke is virtually a must, cam sproket holding tool, flywheel holding tool, chain tentioner and various spanners for undoing the large oil line nuts, micrometers and verniers are just the ones that come immediately to mind. So a quality range of tools need to be factored in if you don't have many of them already. Also invest in some good books on the subject, Workshop manual, bruce andersons performance 911 book and adrain streethers 964 book are well worth a look.
If you plan to do the head work then yet more special tools are required.
There are quite a few special tools which you will have to either purchase or make, ok if you plan to purchase but another skill set to add if you don't. In particular a decent engine stand and yoke is virtually a must, cam sproket holding tool, flywheel holding tool, chain tentioner and various spanners for undoing the large oil line nuts, micrometers and verniers are just the ones that come immediately to mind. So a quality range of tools need to be factored in if you don't have many of them already. Also invest in some good books on the subject, Workshop manual, bruce andersons performance 911 book and adrain streethers 964 book are well worth a look.
If you plan to do the head work then yet more special tools are required.
gregmarshall
New member
This is all good stuff. I have spent about a year so far just planning/reading/researching this subject...
gregmarshall
New member
Yes I read your article and to be honest was fairly inspired by it - top work!
Dekker
New member
I've just read Ian's rebuild online. Well done Ian and great pictures too.
I don't need to work on my engine at the mo' but would go for it if I needed to.
You know that the engine rebuild will be done to the high and demanding standards (your own), also all those little jobs with ancillaries like cleaning and repainting would get done too. Like powder coating the tin ware to inhibit corrosion etc.
Go for it Greg.
What part of the country are you?
I don't need to work on my engine at the mo' but would go for it if I needed to.
You know that the engine rebuild will be done to the high and demanding standards (your own), also all those little jobs with ancillaries like cleaning and repainting would get done too. Like powder coating the tin ware to inhibit corrosion etc.
Go for it Greg.
What part of the country are you?
gregmarshall
New member
Hi Dekker - I'm in Nottingham.
I think i'm going to go for it! - Marcus get your overalls on...!
One question I have - is it likely that i'll need to replace the pistons/barrels? Do they suffer from 'ovalling' given the boxer config?
Ian - any idea how much your rebuild cost, excluding your time?
Does anyone have an engine yoke they want to hire out?
Best Regards,
Greg
I think i'm going to go for it! - Marcus get your overalls on...!
One question I have - is it likely that i'll need to replace the pistons/barrels? Do they suffer from 'ovalling' given the boxer config?
Ian - any idea how much your rebuild cost, excluding your time?
Does anyone have an engine yoke they want to hire out?
Best Regards,
Greg
Dekker
New member
From what I've read most rebuilds need new rings only with the glaze removed from the bores.
Most work is in the valve seats and stems replacing tin ware and replacing broken studs, timing gear and remedial work on cam shafts.
Of course every engine is different.
Some go the whole hog and replace the crank bearings and balance the rods and pistons, which I must admit I would do if I'd gone to the bother of removing the engine.
You're not too far away to lend a hand on a day I feel like getting my hands dirty.
Most work is in the valve seats and stems replacing tin ware and replacing broken studs, timing gear and remedial work on cam shafts.
Of course every engine is different.
Some go the whole hog and replace the crank bearings and balance the rods and pistons, which I must admit I would do if I'd gone to the bother of removing the engine.
You're not too far away to lend a hand on a day I feel like getting my hands dirty.
gregmarshall
New member
Well you'll be very welcome to lend your brain/hands!
On the issue of engine removal - do you think it's possible to remove the engine and gearbox by just jacking the back of the car up really high? I'm sure it's doable without a ramp...
On the issue of engine removal - do you think it's possible to remove the engine and gearbox by just jacking the back of the car up really high? I'm sure it's doable without a ramp...
Dekker
New member
ORIGINAL: gregmarshall
Well you'll be very welcome to lend your brain/hands!
On the issue of engine removal - do you think it's possible to remove the engine and gearbox by just jacking the back of the car up really high? I'm sure it's doable without a ramp...
I can't help you on that one as I've never taken the engine/gearbox out of a 911.
I did the same with a VW van and it came out clean. Rebuilt it while living in it parked on bricks in a friends front garden, much to his wife's disgust. Those were the days
I've rebuild lotus engines and gearboxes, and a mini engine highly modified and gas flowed in my youth.
gregmarshall
New member
Hi Dekker,
Thanks for the link - always great when people post good quality photos..
I've started (Sort of!) My Tax ran out end of Feb and the motor's SORN. I have ordered a couple of books that Laurence recommended from Amazon, I have the full workshop manual, Porsche Restoration manual plus both Bentley books so I've at least ticked the bedtime reading list! I have a couple of jobs to get out of the way first - I have a new bonnet and an RS rear bumper that I've prepped ready for primer, plus I have my best friend's motorbike in pieces that needs rebuilding to create some space - that project is currently just the engine in the frame at the moment but it's gotta go to make room for the rebuild!
I'm also lucky to have a mate who lives on the next street who's currently converting his 3.2 to an RSR spec pre 73 in his garage. He's built more engines than i've had hot dinners and he's up for helping get me rebuild too.
I read in the Haynes Complete Resto manual that the PCGB can hire you the special tools and the yoke - is this still the case? Any ideas anyone?
I'll keep you posted but i've got a fair bit of work to do before I can even start on the engine, some tools to precure, motorbike to shift etc. blah...
Thanks for the link - always great when people post good quality photos..
I've started (Sort of!) My Tax ran out end of Feb and the motor's SORN. I have ordered a couple of books that Laurence recommended from Amazon, I have the full workshop manual, Porsche Restoration manual plus both Bentley books so I've at least ticked the bedtime reading list! I have a couple of jobs to get out of the way first - I have a new bonnet and an RS rear bumper that I've prepped ready for primer, plus I have my best friend's motorbike in pieces that needs rebuilding to create some space - that project is currently just the engine in the frame at the moment but it's gotta go to make room for the rebuild!
I'm also lucky to have a mate who lives on the next street who's currently converting his 3.2 to an RSR spec pre 73 in his garage. He's built more engines than i've had hot dinners and he's up for helping get me rebuild too.
I read in the Haynes Complete Resto manual that the PCGB can hire you the special tools and the yoke - is this still the case? Any ideas anyone?
I'll keep you posted but i've got a fair bit of work to do before I can even start on the engine, some tools to precure, motorbike to shift etc. blah...
gregmarshall
New member
I got the Haynes Resto off Amazon. I bought it when I was rebuilding my SC so it's engine stripdown and rebuild is of an earlier engine. Still very useful read. There's loads on bodywork in it too but fairly general.
Workshop manual was a pressie from the father in law - another fellow 964 owner and all round petrolhead
Do you have the Bentley Enthusiasts Book?
Does anyone rate it as a reference?
Workshop manual was a pressie from the father in law - another fellow 964 owner and all round petrolhead
Do you have the Bentley Enthusiasts Book?
Does anyone rate it as a reference?
gregmarshall
New member
550 nearly built - tank and panels off to paint soon so gaining ever more of the garage back ready to take the porker apart
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