[928uk] GT engine fitted and running

Wed Sep 30 06:19:55 UTC 2015

Thanks Phil,

Forgot to add to the acknowledgements, 
Stotfold Plating, excellent job, couldn't had done it any cheaper myself, and unlikely to get as good a finish.

Cheers 
Sean 

Sent from my iPhone

> On 30 Sep 2015, at 06:58, Phil rick <rickphilse at gmail.com> wrote:
> 
> hi Sean
> that looks gorgeous.
> there is nothing more satisfying than hear it run after you have done all that work is there
> 
> who did the clear zinc coating for you?
> that just finishes it off to perfection
> 
> cheers
> Phil
> 
>> On Tue, Sep 29, 2015 at 11:54 PM, Sean Baker via 928uk <928uk at lists.928.org.uk> wrote:
>> All done, back up and running and sounding so sweet:
>>  
>> https://www.flickr.com/photos/126134086@N07/
>>  
>> Thoroughly enjoyed the whole job, although it takes a lot of time and a lot of space to store all the bits that are removed. Removing, stripping and building in a single garage presented its challenges, fortunately mine is just long enough to work on the removed engine in front of the car.
>> Not all I done was necessary but as I was there I replaced or refurbished all I thought might be necessary at some point and refreshed cosmetically the rest as best possible. The only visible or measured engine wear was on the main bearings, cam belt sprockets and a little pitting on a couple of camshaft lobes. 
>>  
>> All the work completed from the bottom up:
>>  
>> Complete engine gasket set fitted.
>> All big end and main bearings replaced, as originals showed slight wear.
>> Crank shaft journals polished, specialist engine engineering company (SEEC) used
>> Block fully stripped, some sheered bolts removed by SEEC, bolts sheered as excessively corroded in situ. One thread helicoid fitted. One stud removed at the water pump mating surface, sheered bolt inherited from PO.
>> No lip to be concerned about on any of the piston bores.
>> Piston rings inspected, carefully removed and located in the bore and checked ring gap, measured and no excessive wear.
>> Rebuild bottom end.
>> Oil pump sprocket replaced, excessive wear to the teeth. Note, the original was lightweight material like the camshaft sprockets, the new one was steel (only option available from Porsche).
>> Heads, fully stripped, new valve guides fitted, all valves and seats re-cut and lapped in.
>> 32 valve lifters replaced. Most did not retain oil pressure..
>>            No brief tapped noise now when staring.
>> Cam sprockets replaced, good condition second hand ones.
>> New cam belt
>> New tensioner bushes and roller
>> Tensioner refurbished. Was seized, no oil inside.
>> All cam cover bolts and washers polished and clear zinced.
>> Cam covers refurbished, magnesium alloy power coating specialist used. Porsche inlay painted by me.
>> Induction chamber refurbished, again magnesium alloy power coating specialist used. Lettering painted by me.
>> Flappy and throttle body bearings replaced.
>> Throttle body switch repaired.  Carefully prised apart, re-soldered internal connections, ultrasonic bath cleaned and cam re-greased. Reassembled with rubber bonding/sealant.
>> New ISV fitted
>> Refurbished 4 hole injectors fitted
>> All metal bits cleaned, shot blasted or polished and clear zinced. (There is a lot of them)
>> Rubber fuel line replaced
>> Small throttle cable replaced
>> Oil lubricated main throttle cable, (no longer have a stiff throttle)
>> Exhaust emission air input lines shot blasted and clear zinced
>> Air pump damaged by me when stripped for repair and cleaning. Will fit another one eventually.
>> New Knock sensors
>> New Crank position sensor
>> New Water value
>> New Beau HT leads.
>> New rotor arms
>> New dizzy caps
>> New Vacuum elbows
>> New slave clutch assembly.
>> Fortunately the clutch had plenty of material left, presume it’s not the original from new.
>> Thoroughly cleaned engine bay.
>> New oil, Valvoline VR1 20/50
>> New antifreeze, Comma G38
>> New PS fluid, Comma
>> New filter, Mann
>> AC pump strip and rebuild, new seal kit fitted.
>> AC lines shot blasted and clear zinced
>> All AC seals replaced at all pipe joints
>>  
>> Acknowledgements:
>>  
>> Thanks to :
>>  
>> Roger Tyson for the supply of most of the parts.
>> Richard at Porsche Hatfield for supply of the rest.
>> STPC for the specialist powder coating
>> Hydraquip of Letchworth for the PS lines and assistance.
>> Norton Way Fasteners for the supply of many a bolt and washer
>> T & L Engineering, specialist engine engineering company
>> You lot for advice when needed
>> Alex Popov for this info….replace the valve lifters with golf 16v INA’s, as same but vastly cheaper
>> Simon Painter for doing it first and making me think “wow”, what they can look like under the bonnet.
>> Angus for providing this medium to give me/us the support and information when needed and the confidence knowing there is always an answer at the end of an email…
>>  
>> And the 928 GT for regenerating my love of driving with, lets just say, enthusiasm….
>>  
>> 250 miles of smiles already.
>>  
>> Cheers
>> Sean 89GT
>>  
>> 
>> _______________________________________________
>> 928uk mailing list
>> 928uk at lists.928.org.uk
>> http://lists.928.org.uk/cgi-bin/mailman/listinfo/928uk
> 
-------------- next part --------------
An HTML attachment was scrubbed...
URL: <https://lists.928.org.uk/pipermail/928uk/attachments/20150930/a0719abe/attachment.htm>