Parts
 

Still much to come, but I just received first parts last Saturday,

have you measured the cylinders for ovality and taper? It looks like you intend to reuse the 5 cylinders and add one new piston?

As you understand I’m gone need a other set of intake manifolds, As the used market is full of good units I will look there, Here comes the question! which one is the best (cheap) if I’m looking for some more power???
986/987, 3.2
987, 3.4
911, 3.6
etc.....

Im playing with the idea using the units I purchase (cutting and 3d scaning them) to make my own version in composite.

Yes, I left this to a local machinshop who take care of this,

I always use to weight the pistons before i assemble them to the engine, The new piston arrived weighting 540g and when I put the old units at the scale the weighted 543g....
But after cleaning carbon the made the same 540g as the new unit.
So 3g carbon weight at each piston..mmmm



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Was that with the wrist pin?

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I went to the machine shop picing up the cylinder heads today, The damage one with new valve guides, Valve seats and with six new exhaust valves,

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I`m rebuilding this engine just to have something fun to use until i finish a more powerful unit for this car.

As I didn’t unassembled the engine and it’s no way for me to know if there any lost parts, bolts etc. I will just put everything together first before I glue it together with gaskets and Loctite,



I will handle over the cylinder block tomorrow to the machine shop to make the IMS hole bigger using a CNC milling machine.
This way I can change the IMS ballbearing everythime I change clutch.
At the lefthand side you have the improved IMS and at the righthand side the OEM unit, increasing diameter at the engine block IMS hole to 62mm it will be no problem changing this in the future...
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I sent the engine block to mechanise milling IMS hole opening it up to take the new 62mm IMS. It`s looks great!
Under my point of view I don’t see milling the whole with the engine in place at the car as several companies sell, perform or rent, As I see it no matter how careful you are it will always come in a lot off metal shavings in the engine who will go around whole oil cirquit damaging the engine.
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Oem
 

At the final I haven’t changed nothing from stock parts rebuilding the engine, I have just rebuilt the with the idea of build an second more hot engine making a coming swap in the future.
As I had everything just mixed up in boxes it’s been like puzzle, driving me crazy..
Nothing was marked as it should have been etc…
But now engine is together and finished but with one little shaft left over ho I can’t find out from where it comes or goes, this driving me crazy!

If anyone knows anything about this shaft please help!

Photos of the little shaft/axle

Assembling process
 

Some pics putting together the engine, at the last pics you have a hint why of my nickname :rolleyes:

Finished…
 

The engine is now finished excepto for one berating hose that’s on its way by post

Nice progress. Where did the shaft go?

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Finished or may not?
 

I still haven’t no idea where this bloody shaft goes, as I they gave me the engine totally unassembled in boxes 📦 there is a possibility the shaft not from this engine, the thing is, this kind of engines I divided in two identical half’s, why just one shaft?
This is getting me a bit on my nerves……

I now have the engine finished except for one breathing hose who still haven’t arrived.
Shaft
Shaft
Shaft
:eek:

Very nice work.

For a decent skilled DIY, with access to some general tools, but nothing Porsche propriety specialty tools - how hard would it be to do IMS or even engine rebuild?

I had done engines rebuilds, but that was much smaller units or much simpler. The smallest was a 650 cc in Fiat 126p, the largest was 3.8 V6 Pontiac Bonneville.

So yeah - is it doable or one must have very special tools?

The only special tool you absolutely must have is the one to put on the piston rod and locking clip

Brumm brummmm
 

I had the engine in (not the easiest thing, I have to admit!) finally, I test started it up for about 10sec and everything sound ok (I believe), This was just a short test without any cooling liquid, exhaust, driving shafts, AC plumping etc connected.
As I now news it do start, I will connect all the rest tomorrow afternoon!

Congtratulations, you are in the home stretch now!

My old back are completely destroyed after pulling in the engine….
But what a great feeling!!!!!