Turbo Engine Rebuild
- Thread starter scam75
- Start date
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scam75
Well-known member
At last a few updates! It turns out it takes a while for bespoke pistons to me made, however my forged JE uncoated pistons will be ready tomorrow and with my engine builder shortly afterwards.
The engine builder has come across another issue in the time being, a broken head stud has been bodged at some point with a dose of liquid metal. This has resulted in the thread stripping a bit. Anyway a permanent proper solution will now take place with the repair requiring a new head stud to be fabricated. I've posted down a couple of cylinder head nuts for them to get the thread spot on. I have also sent down my little connector for the steam vent kit so this can be installed whilst they still have the engine.
So we should be pretty much on the home straight now with all disasters (eventually) resolved. Engine should be ready 2nd week in March then with a bit of luck be back in the car and purring by the end of March. I've genuinely forgotten I own a Porsche it's been away so long. Good to know I'll soon have a new 944 turbo with fresh engine, cometic HG, new bespoke forged pistons, new uprated clutch, steam vent kit, strengthened oil pick up pipe and lots of other new and shiny things I've totally forgotten about!!
Stuart
The engine builder has come across another issue in the time being, a broken head stud has been bodged at some point with a dose of liquid metal. This has resulted in the thread stripping a bit. Anyway a permanent proper solution will now take place with the repair requiring a new head stud to be fabricated. I've posted down a couple of cylinder head nuts for them to get the thread spot on. I have also sent down my little connector for the steam vent kit so this can be installed whilst they still have the engine.
So we should be pretty much on the home straight now with all disasters (eventually) resolved. Engine should be ready 2nd week in March then with a bit of luck be back in the car and purring by the end of March. I've genuinely forgotten I own a Porsche it's been away so long. Good to know I'll soon have a new 944 turbo with fresh engine, cometic HG, new bespoke forged pistons, new uprated clutch, steam vent kit, strengthened oil pick up pipe and lots of other new and shiny things I've totally forgotten about!!
Stuart
scam75
Well-known member
Ha ha! Yes thanks, 5 months is not too bad I suppose, would have been much quicker without the piston carry on but here we are!
My MOT has run out during my lay off, so that will need done too, no advisories last year and haven't covered a lot of ground so should be a formality!
Stuart
My MOT has run out during my lay off, so that will need done too, no advisories last year and haven't covered a lot of ground so should be a formality!
Stuart
scam75
Well-known member
Well we are nearly there now, the short motor is built up, balance shaft bearings a tad grumbly, so new ones ordered (would be foolish not to having come this far!), once these are fitted then everything is ready to go on a pallet and head back North! £22 quid each x 4 for the balance shaft bearings if anyone wanted to know, ordered from Porsche.
Spoke to my mate and it looks like early April before he can dedicate the time to put it back together. I'm off to Portugal for a week on Saturday so I'll likely head down to the garage after that and get some pictures of the engine and get some timescales for the work to be done. Exciting times!!
Stuart
Spoke to my mate and it looks like early April before he can dedicate the time to put it back together. I'm off to Portugal for a week on Saturday so I'll likely head down to the garage after that and get some pictures of the engine and get some timescales for the work to be done. Exciting times!!
Stuart
scam75
Well-known member
Well that's the engine work completed. Total came to £4,421 inc. vat. A definite gulp moment and about £800 over the original estimate. However no stone has been left unturned. So, if I remember correctly (or maybe I'll look ay my list!), this includes new bespoke JE forged pistons, cast iron repair liners, modify liners to suit application, oil pick up pipe strengthener, head adapted for steam vent kit, stepped stud solution for damaged head stud/thread (now M16 in block and exposed stud M12, pretty solid!), head gasket set, bottom end gasket set, correct thickness cometic HG, main bearing set, big end bearing set, bore block to suit flanged liners and fit liners, bore and hone cylinder block with torque plate fitted, reface cylinder block to flat, reface block top with liners fitted to obtain correct protrusion, remove and refit studs to block top, reface cylinder head, check and polish crankshaft, check con rods for size and hone if necessary, strip + wash off parts + inspect parts + rebuild short motor, 4 x balance shaft bearings.
On top of this I've had to acquire a nearly new oil pump (free, thanks Simon!) and also a full clutch kit including uprated cup friction plate (at £410 this ended up cheaper than a stock kit), steam vent kit (£46) and I'm already out £685 for parts needed at my end for refitting to car.
Total so far: £5,562. I still have to pay for the labour at this end for removal/strip/rebuild/re-fit to car. Wild guess this probably be at least another £1.5k.
So all in about £7k. Had budgeted for £6k but the JE pistons ended up dearer than the original Wossners (£100 or so, not too bad for bespoke), the stud issue to fix, balance shaft bearings and other incidentals that I've forgotten at the engine builder.
So what do we think, I'm hoping this represents fairly good value for money and a good solution and a mostly fresh engine that should outlast me!
Cheers
Stuart
On top of this I've had to acquire a nearly new oil pump (free, thanks Simon!) and also a full clutch kit including uprated cup friction plate (at £410 this ended up cheaper than a stock kit), steam vent kit (£46) and I'm already out £685 for parts needed at my end for refitting to car.
Total so far: £5,562. I still have to pay for the labour at this end for removal/strip/rebuild/re-fit to car. Wild guess this probably be at least another £1.5k.
So all in about £7k. Had budgeted for £6k but the JE pistons ended up dearer than the original Wossners (£100 or so, not too bad for bespoke), the stud issue to fix, balance shaft bearings and other incidentals that I've forgotten at the engine builder.
So what do we think, I'm hoping this represents fairly good value for money and a good solution and a mostly fresh engine that should outlast me!
Cheers
Stuart
Dan944t
New member
scam75 said:
nice one Stuart!! ive not been on for a while due to busy homelife with kids ect. …
if it makes you feel better,… my engine build parts and machine work like yours with custom linners , bespoke rods , race pistons , oil scrappers , head porting ect ect , everything else from porsche cost me just over £8,000 and i totally built the engine myself! imagine if i didn’t ,…
tgat was nearly 4 years back now , not started it yet as i’m still in middle of fitting a lorry holset turbo with twin scroll , ( hopefully this summer ??) ALLOT of awkward custom work ahead of me,…. so i’m also missing my 944 badly!
so much so that i bought myself a 3.2S 986 so i’m not withought one till i do
looking forward to you driving it mate , as i know exactly how your feeling
atb
Daniel
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