Cylinder Heads and Camshaft Housings Installed

A few more steps to completion.

Heads Installed, Left Camshaft Housing Test Fit

Heads Installed, Left Camshaft Housing Test Fit

Camshaft Housings Installed, Knock Sensors Installed

After a great deal of agony over the choices, I used Threebond 1184 for sealing the camshaft housings to the cylinder heads.  Fingers crossed I did it well!

On the knock bridge and knock bridge sensor, I used a bit of purple Loctite with the appropriate primer.  Apparently the aluminum hole and plated steel fastener may not be enough to "cure" the Loctite.  Given the engine's heat and the temperatur profile of the Loctite, I am somewhat skeptical that this will do much, but I figured it wouldn't hurt much either.

P&C's Installed

Noting a little milestone along the way...pistons and cylinders installed.

Little sections of PVC pipe work great if you don't have enough spare sockets to hold the cylinders in place.  I used left-over 3/4" schedule 40 from the clean room construction, but a smaller diameter would probably be a bit better.

Engine reconstruction commences!

Family heads out, wrenching commences

With the family off to the grandparents' for the weekend (thanks everyone!), I set about beginning engine reconstruction.  However, before that could begin, I needed to finish building my "clean room".  I thought about just reserving the garage for engine building, but given my rate of progress, that didn't seem like a good idea.

The clean room complete

It has AC!

Ready to begin

A ding in the cylinder-head mating surface - the next bump in the road. But this piston looks good!

Piston when first disassembled

SAI Pump Wire Insulation

A known weakness, the insulation falls of the wires leading to the SAI pump.  I addressed it by knocking off the old insulation and replacing it with Ancor marine-grade shrink wrap (1/4").  Not only did this shrink wrap seem extra sturdy, but it shrinks to 1/3 it's original diameter.  This allows it to clear the collar on the plug and still shrink tight around the wire.  But next time, I would probably just replace the wires.

Engine Pad Replacement

Out with the old

As is common, my 993's engine pad was in sad shape.  There is no easier time to replace it than when the engine is out...

The Fan/Fan Housing Saga

Broken Blade Tip

At the beginning of my top-end rebuild, I was excited about the opportunity to refinish my decrepit-looking 911 engine cooling fan and housing.  Once they were removed, however, I realized they were both damaged beyond repair.

The Damage

The fan was missing two blade tips, and the fan housing was cracked around the alternator mount.  So I decided to bite the bullet and order both new.  I figured it would at least be easy, but Porsche had something else in store for me...

Plated!

Progress has been slow over the last few months (three months since the last post!?!), but it hasn't completely ground to a halt.  The big news this weekend - parts are back from being yellow-zinc plated!

The freshly plated oil-filler cap might be the first part I have re-installed, which seems like a landmark worth capturing :-).


More pictures below...