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Chris G
Trainee


Joined: 31 May 2015
Posts: 77



PostPosted: Tue Oct 18, 2016 2:52 pm    Post subject: Rebuild woes... Reply with quote

Hey,

My 964 started to sound very rough a couple of weeks ago, so I dropped into Unit 11 and they found metal fragments in the oil. Cue the engine being taken out and stripped down today...

Needs new oil tank, cooler & pump and pistons & cylinders so far. They also found a jubilee clip in cylinder 2, which has probably caused some more damage which I'm waiting to find out. Not sure how that ended up in there.

Crank is going to get measured at some point today or tomorrow.

The car is still on the dual flywheel, so will also be going for an RS clutch and flywheel whilst its all out.

So far he is roughly up to £10,000! I'm trying my hardest to convince myself that its money well spent and that I didn't actually need the money I saved up for my house!

The car is properly under my skin and I feel sick. So gutted
 
  
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Zingari
Donnington
Donnington


Joined: 25 Oct 2009
Posts: 12596
Location: Cheshire

1993 Porsche 964 Anniversary

PostPosted: Tue Oct 18, 2016 4:30 pm    Post subject: Reply with quote

Surprised What's the year/mileage? I'll be interested to find out the cause especially if there is a suggestion of a rocket shaft bolt coming loose and fouling a cam. I'm convinced this is a factor in top end rebuilds what

Unit11 - You're in safe hands Thumb
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Alfa Romeo’s 4C is everything a Italian sports-car should be: it’s gorgeous to the point of pornography, distinctive enough that nobody will ever mistake it for a Porsche, handles like it’s on rails and steers like a kart.
 
  
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SEE YA
Barcelona


Joined: 19 Aug 2003
Posts: 1349
Location: United Kingdom South West.


PostPosted: Tue Oct 18, 2016 5:06 pm    Post subject: Reply with quote

You drive you pay, found that out myself some bills small others huge.

My gearbox bill doubled, from the first quote until you open them up you never know same with a engine.
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EVERY MILE IS A SMILE

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Gazc2
Kyalami


Joined: 08 Nov 2003
Posts: 1750
Location: Scotland


PostPosted: Tue Oct 18, 2016 6:19 pm    Post subject: Reply with quote

Chris,

I am truly gutted for you mate and how on earth can a jubi clip get in a cylinder ?

How many miles you done since you got it

Gaz
_________________
2007 997 Turbo & 924s in progress
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 
  
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Chris G
Trainee


Joined: 31 May 2015
Posts: 77



PostPosted: Tue Oct 18, 2016 6:50 pm    Post subject: Reply with quote

Engine was a reconditioned unit put in a few years ago on around 80k I think, done maybe another 15k since then. Thats if my memory is right

I'm going to see the damage tomorrow, but don't know the full extent of the build yet.

I've probably done 3-4k in the car since I had it. I'm gutted, but know that once I get the car back it will be sweet as a nut and a well sorted example.

Got to expect a big bill every now and again. Just knocks it out of you when you hear these sorts of figures haha
 
  
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stuttgartmetal
Indianapolis


Joined: 23 Feb 2009
Posts: 2373
Location: Caterham. Surrey


PostPosted: Tue Oct 18, 2016 9:03 pm    Post subject: Reply with quote

C2 ?
 
  
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Frenchmeister
Suzuka


Joined: 24 Feb 2014
Posts: 1245
Location: Beautiful Cumbria.

2004 Porsche 997 Carrera 2S

PostPosted: Tue Oct 18, 2016 9:21 pm    Post subject: Reply with quote

Another Unit 11 thumbsup keep us posted.
And everyone slags 997's off btw.
Yes I have a 997.
Grin
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sam
Monza


Joined: 28 Feb 2009
Posts: 158



PostPosted: Tue Oct 18, 2016 11:28 pm    Post subject: Re: Rebuild woes... Reply with quote

Chris G wrote:
Hey,

My 964 started to sound very rough a couple of weeks ago, so I dropped into Unit 11 and they found metal fragments in the oil. Cue the engine being taken out and stripped down today...

Needs new oil tank, cooler & pump and pistons & cylinders so far. They also found a jubilee clip in cylinder 2, which has probably caused some more damage which I'm waiting to find out. Not sure how that ended up in there.

Crank is going to get measured at some point today or tomorrow.

The car is still on the dual flywheel, so will also be going for an RS clutch and flywheel whilst its all out.

So far he is roughly up to £10,000! I'm trying my hardest to convince myself that its money well spent and that I didn't actually need the money I saved up for my house!

The car is properly under my skin and I feel sick. So gutted


Would have thought you could get a fully refurbed motor for that kind of money, or a bit less? can't imagine how it ran for more than ten minutes with a jubilee clip inside a barrel . Terrible news though.
 
  
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Marky911
Kyalami


Joined: 04 Jun 2009
Posts: 1928



PostPosted: Wed Oct 19, 2016 4:40 am    Post subject: Reply with quote

Ah man! Nightmare. Been through it a few times on 911s I've had. That sinking feeling when you get the costs in.

Will be good when it's sorted but that's little consolation at the moment.

As for the post above suggesting a fully refurbed motor for less than £10k, I'd say no way unfortunately. Stick with what you have and get it rebuilt by someone good, Unit11 fit the bill by all accounts so you're in safe hands.
A decent top end rebuild will be £5k+. Once you start adding in pistons and barrels and everything else then £10k is the norm.

My 996 is with my Indy this week for a service and a few niggles. First time he's seen it since I bought it. I dread the phone ringing to say what he might have found. Grin It hasn't gone in for anything like that but you never know. I always remember taking my first 911 in for what I thought was a blowing exhaust manifold only to be told it was snapped head studs. Cue the engine rebuild. First of a few over different cars.

My ethos.... Do it right, do it once. You only want to be in there once so change anything that's worn. That will probably extend to a few hundred pounds worth of tin-ware, then all the little bits like gaskets, seals, cam chains. It really mounts up.

You can always sell as is but if you really like it then I guess that's not an option.

Good luck. Thumb
 
  
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ras62
Montreal


Joined: 20 Jan 2012
Posts: 617
Location: Cheshire


PostPosted: Wed Oct 19, 2016 8:06 am    Post subject: Reply with quote

I saw Chris's motor yesterday and it was not a pretty picture. The guys found the remains of a small jubilee clip trapped behind inlet valve #2, it had obviously been bounced around for a long while before finally being nibbled by the valve and tiny piece by tiny piece ingested by the motor....You just cant get rid of debris like that once it's in the oil system without replacing the tank / cooler / pump otherwise you will likely have a repeat.
How did the clip get there? Only way is when the plenum and/or inlets have been off at some point. Its an easy mistake to make in that small space unfortunately.
 
  
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Gazc2
Kyalami


Joined: 08 Nov 2003
Posts: 1750
Location: Scotland


PostPosted: Wed Oct 19, 2016 10:51 am    Post subject: Reply with quote

Well as a lot of you are aware this is my old car an the plenums and inlets were off to get powder coated etc so was it at this point the jubi got in I honestly don't jnow if you look at the pictures in my thread the first thing I done was block of the inllets which didn't come out until the the plenum went back on so struggling to see how it got in there as Chris mentioned it was a replacement engine which had been in and out a couple of times due to it not running properly before I bought it so could it have been then I honestly don't know either way I feel for Chris also amazed how it can run ok for 5-6000 miles with this issue.

Gaz
_________________
2007 997 Turbo & 924s in progress
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 
  
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ras62
Montreal


Joined: 20 Jan 2012
Posts: 617
Location: Cheshire


PostPosted: Thu Oct 20, 2016 8:59 am    Post subject: Reply with quote

Mistakes happen Gaz so who knows for sure. It could have lodged in the horizontal part of the inlets before finding its way down to the valve but even down there it would take a long time of being battered around before small fragments started to go into the motor.
Its done but Chris is in safe hands. The engine he gets back will be superb and wont cost some of the silly figures you read on forums.
 
  
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Chris G
Trainee


Joined: 31 May 2015
Posts: 77



PostPosted: Thu Oct 20, 2016 4:45 pm    Post subject: Reply with quote

Went to see the car yesterday and give the go ahead for the work to go ahead, after a brief flirt with going for a 3.8 build. But cost killed that one for me as I'm generally happy with the car as it is and the £11k it's costing with the RS clutch and flywheel is enough!

As Rob has said the engine was in a bad way. I'm surprised it lasted the 5-6k as well. At a guess its been rattling around in there without issue but has finally been broken down enough to cause an issue. The car drove fine the day I took it in to Unit 11, just sounded horrible, so lucky I heard it and got it in to the guys before more damage was caused.

How the jubilee clip got in there does not matter, it's one of those things and I was expecting to have to get the motor rebuilt at some point anyway. Once the car is back with me I know I'll have a well sorted car as the rest of the car really is in top condition and all the work carried out to a high standard.

I just want it back now, obviously depending on the time it takes for parts to come, I should have it back within 3-4 weeks. Gives me a couple of weeks to give the garage a spruce up I suppose!
 
  
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Palladium
Indianapolis


Joined: 01 Nov 2015
Posts: 2496



PostPosted: Thu Oct 20, 2016 4:57 pm    Post subject: Reply with quote

oh, its a horrible feeling justifying the expense, I got hammered twice for mechanical and electrical repairs recently.

You never get that money back, I don't care what people say.


How many miles were on your car?


All these rebuilds and failures, I think most of these cars have done double the miles the clock says.


Good luck. Thumb
 
  
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SEE YA
Barcelona


Joined: 19 Aug 2003
Posts: 1349
Location: United Kingdom South West.


PostPosted: Thu Oct 20, 2016 5:22 pm    Post subject: Reply with quote

Palladium wrote:
oh, its a horrible feeling justifying the expense, I got hammered twice for mechanical and electrical repairs recently.

You never get that money back, I don't care what people say.


How many miles were on your car?


All these rebuilds and failures, I think most of these cars have done double the miles the clock says.


Good luck. Thumb


It's all about 'EVERY MILE IS A SMILE '

Plus I tell the wife it only cost this and not the real cost Very Happy
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Bonners1
Spa-Francorchamps


Joined: 09 Sep 2008
Posts: 265
Location: Gerrards Cross


PostPosted: Thu Oct 20, 2016 8:43 pm    Post subject: Reply with quote

Chris G wrote:
Went to see the car yesterday and give the go ahead for the work to go ahead, after a brief flirt with going for a 3.8 build. But cost killed that one for me as I'm generally happy with the car as it is and the £11k it's costing with the RS clutch and flywheel is enough!

As Rob has said the engine was in a bad way. I'm surprised it lasted the 5-6k as well. At a guess its been rattling around in there without issue but has finally been broken down enough to cause an issue. The car drove fine the day I took it in to Unit 11, just sounded horrible, so lucky I heard it and got it in to the guys before more damage was caused.

How the jubilee clip got in there does not matter, it's one of those things and I was expecting to have to get the motor rebuilt at some point anyway. Once the car is back with me I know I'll have a well sorted car as the rest of the car really is in top condition and all the work carried out to a high standard.

I just want it back now, obviously depending on the time it takes for parts to come, I should have it back within 3-4 weeks. Gives me a couple of weeks to give the garage a spruce up I suppose!


Sorry to hear of the problems, but impressed with your attitude. What's done is done, the expense is what it is so look forward to getting a well sorted car back next month. Thumb
 
  
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Chris G
Trainee


Joined: 31 May 2015
Posts: 77



PostPosted: Fri Oct 21, 2016 8:06 pm    Post subject: Reply with quote

Thanks for words of support.

Car is on 163k I think, but engine is on about 80kish I think.

The car has had a little make over since I bought the car, new tailights and reflector, new wheels and a RUF front splitter, so once back, will be posting some pictures. Been meaning to for ages now
 
  
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deutschland-dobson
Indianapolis


Joined: 23 Apr 2008
Posts: 2456
Location: NE England


PostPosted: Fri Oct 21, 2016 8:16 pm    Post subject: Reply with quote

Looking forward to seeing the photos! Bet you can't wait to get her back. Plenty of miles to look forward to!

Chris
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Chris G
Trainee


Joined: 31 May 2015
Posts: 77



PostPosted: Mon Oct 31, 2016 6:20 pm    Post subject: Reply with quote

Been to see the car today, its coming along nicely, hoping to get it back next week. Need to go back through the history of the car, but thinking a cause of needing a lot of the work was due to metal fragments, from a previous failure, in the oil tank/cooler etc. Not sure if these were replaced when this engine was dropped in, so could have had metal fragments from the bearings failing last time and thats just been circulated round again causing more damage.

But for now, roll on next week! I can't wait
 



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Chris G
Trainee


Joined: 31 May 2015
Posts: 77



PostPosted: Fri Nov 04, 2016 4:05 pm    Post subject: Reply with quote

Hopefully picking the car up on Monday. But with a blown LHS heat exchanger as well now.

That good attitude to the car and all this work has now gone! Well and truly!

If anyone knows someone who has a decent LHS heat exchanger for sale, please contact me
 
  
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