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Harv
Suzuka


Joined: 18 Sep 2014
Posts: 1001



PostPosted: Mon Dec 05, 2016 5:30 pm    Post subject: 3.9 Engine Build Reply with quote

Thought I'd throw up a thread detailing my engine build as a thank you to some of the businesses and members on here and it maybe of some use for others contemplating similar works.

I finally have enough parts in hand to make a start and this will be a full refresh at 120k and upgrades that seemed to make sense while the unit was in bits. All new bearings, chains throughout and lots of cleaning, measuring and cleaning again prior to assembly.

Crank, lightweight flywheel, clutch cover and underdrive pulley balanced as a unit to within 1/10th of a gram.

Basic components of the bottom end ready for assembly


Are you sure it clean? Clean it again!


New bearings fitted


Crank in place, bearings pre lubricated


Bolts torqued up, i added a few more reps to the sequence and check for no tight spots as we went. The marks only indicate that that particular bolt has been torqued to final spec


Crank end float checked and bang within spec at 0.15mm


Still waiting on modified engine cases, more next time


Thumb

Last edited by Harv on Mon Dec 05, 2016 5:48 pm; edited 2 times in total
 
  
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MisterCorn
Zolder


Joined: 08 Jan 2011
Posts: 5107
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Mon Dec 05, 2016 5:32 pm    Post subject: Reply with quote

Excellent, this looks interesting... Thumb

MC
 
  
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Robertb
Long Beach


Joined: 01 Sep 2003
Posts: 6001
Location: South Oxfordshire

2002 Porsche 996 Carrera 4S

PostPosted: Mon Dec 05, 2016 5:49 pm    Post subject: Reply with quote

Nice job! I am in awe of your spanners skills.

What sort of state were the bearings/bores/pistons in?
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infrasilver
Fast & Furious
Fast & Furious


Joined: 04 Oct 2010
Posts: 6924
Location: East Midlands

2001 Porsche 996 Targa

PostPosted: Mon Dec 05, 2016 6:12 pm    Post subject: Reply with quote

Glad it's coming together now Harv, if you don't feel brave fitting the gudgeon circlips let me know.

Are you using assembly lube, I can't see any?
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Harv
Suzuka


Joined: 18 Sep 2014
Posts: 1001



PostPosted: Mon Dec 05, 2016 6:17 pm    Post subject: Reply with quote

Generally the engine was tired and lacked zing...

Top end the valve seat faces were wide and hammered and exhaust valves very shagged and failing



Main bearings, big end bearings and thrust shim all thread bare




Pistons all good but bores becoming oval and quite a lot of blow by going past the rings, though the rings themselves look ok.
 
  
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Harv
Suzuka


Joined: 18 Sep 2014
Posts: 1001



PostPosted: Mon Dec 05, 2016 6:19 pm    Post subject: Reply with quote

infrasilver wrote:
Glad it's coming together now Harv, if you don't feel brave fitting the gudgeon circlips let me know.

Are you using assembly lube, I can't see any?


Thanks for that, though I'm some way from you.

Yes assembly lube used throughout just not seen in these mockups

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infrasilver
Fast & Furious
Fast & Furious


Joined: 04 Oct 2010
Posts: 6924
Location: East Midlands

2001 Porsche 996 Targa

PostPosted: Mon Dec 05, 2016 6:50 pm    Post subject: Reply with quote

Harv wrote:
Yes assembly lube used throughout just not seen in these mockups.


Thumb I knew you wouldn't mount anything dry.
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alex yates
Shanghai
Shanghai


Joined: 06 Mar 2014
Posts: 10411
Location: Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Mon Dec 05, 2016 7:39 pm    Post subject: Reply with quote

infrasilver wrote:

Thumb I knew you wouldn't mount anything dry.


Surprised
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Phil 997
Yas Marina


Joined: 05 Dec 2015
Posts: 8525
Location: Bournemouth,Dorset

2009 Porsche 997 Carrera 4S

PostPosted: Mon Dec 05, 2016 7:54 pm    Post subject: Reply with quote

alex yates wrote:
infrasilver wrote:

Thumb I knew you wouldn't mount anything dry.


Surprised



Floor double Surprised Surprised Very Happy but Harv this looks like it's going to be a thread to watch mate , good luck with the build
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Jamesx19
Monza


Joined: 10 Jul 2015
Posts: 162
Location: Brighton


PostPosted: Mon Dec 05, 2016 8:01 pm    Post subject: Reply with quote

Nice one, Thanks Harv. Will definately follow this thread. I'd like to do something like this in the future.

What vintage is the engine for reference?

cheers
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Harv
Suzuka


Joined: 18 Sep 2014
Posts: 1001



PostPosted: Fri Jan 20, 2017 12:10 am    Post subject: Reply with quote

Sorry for late reply the engine is a 3.6 from 2002

Time for an update:

I should finally have my modified crankcases back from Serdi next week which will allow me to build up the bottom end. They have been fitted with custom made fully wet 99.5mm I.D bore liners.

The collection of assorted bits continues but here are a few pics which details parts going into the rebuild

Match weighted and balanced end to end rod set with ARP bolts






Wossner forged piston set, 4032 Ali, low expansion, coated skirts and NPR ring set. Again these are matched in weight as a set to within 1/10th gram.







Lightweight single mass flywheel which is a work of art but was still way off the level of balance I'm looking for out of the box, more TLC.





New IMS and cam drive chains



Underdrive pulley



997 GT3 throttle body, note the difference in size?



Next time hopefully some pics of the bottom end going back together after a lot more cleaning.

One thing I'm quite keen to do is get the IMS tube assy itself onto the machine to see if there's any out of balance in it and if that can be improved. I'm not sure if this is something that other engine builders have done/do but something I worth checking.

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Osh
Watkins Glen


Joined: 19 Nov 2012
Posts: 2196
Location: Bristol


PostPosted: Fri Jan 20, 2017 8:17 am    Post subject: Reply with quote

Stay Pop Corn Pop Corn Pop Corn

Harv - what a great thread; looking forward to more and seeing the finished project

Good luck


Osh
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alex yates
Shanghai
Shanghai


Joined: 06 Mar 2014
Posts: 10411
Location: Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Fri Jan 20, 2017 8:42 am    Post subject: Reply with quote

I'm wanting on of them there flywheels!!!! thumbsup
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ragpicker
Sepang


Joined: 14 Apr 2013
Posts: 2879
Location: North East England


PostPosted: Fri Jan 20, 2017 8:51 am    Post subject: Reply with quote

Wow! How have I missed this!?

What a thread Harv, well documented too!

Are you balancing it all yourself? If so how do you do that, practically?

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986 S - usually in pieces: http://911uk.com/viewtopic.php?t=112626
 
  
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Harv
Suzuka


Joined: 18 Sep 2014
Posts: 1001



PostPosted: Fri Jan 20, 2017 10:07 am    Post subject: Reply with quote

Flywheel is the TTV racing item and I'm impressed at the quality for the price, sourced through Richard at Coordsport

The balancing has been done by David Martin who's a well known Aston Martin engine builder and local to me, they have their own in house developed machine for balancing automotive, marine and aviation engines. He really knows his stuff, not repeatable here is what he thinks of dual mass flywheels Floor

At the moment I'm trying to find a intake plenum solution for fitting this 997 GT3 throttle body, maybe build something or have a 3D one printed but I don't know anyone off hand Question

Last edited by Harv on Fri Jan 20, 2017 10:47 am; edited 1 time in total
 
  
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maldren
Spa-Francorchamps


Joined: 07 Oct 2016
Posts: 366



PostPosted: Fri Jan 20, 2017 10:28 am    Post subject: Reply with quote

Hi Harv,
I'm sure I've seen a post on a 3D splitter somewhere but a search didn't find it, it didn't even seem to find your post(?!?!?). It would have been within the last few months as I've only had my car since June!
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2003 996.2 C2 Coupe Arctic Silver
 
  
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Harv
Suzuka


Joined: 18 Sep 2014
Posts: 1001



PostPosted: Mon Feb 06, 2017 5:13 pm    Post subject: Reply with quote

Finally I have my engine cases back fitted with their new 99.5mm full wet liners and the machining really is a thing of beauty.





Lots of measuring, gapping piston rings for each and cleaning to do before cases can come together.

Last edited by Harv on Sun Jun 18, 2017 11:55 pm; edited 1 time in total
 
  
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Marky911
Imola


Joined: 04 Jun 2009
Posts: 790



PostPosted: Mon Feb 06, 2017 10:32 pm    Post subject: Reply with quote

Nothing useful to add but watching with interest.

Very impressive. worship
 
  
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DynoMike
Suzuka


Joined: 25 May 2012
Posts: 1238
Location: The Cotswolds

2003 Porsche 996 Turbo

PostPosted: Mon Feb 06, 2017 11:59 pm    Post subject: Reply with quote

Looking good Harv! Liners look meaty and strong.

Dave Martin is a good old boy Thumb Good luck with the rest of the build, will follow with interest.
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Harv
Suzuka


Joined: 18 Sep 2014
Posts: 1001



PostPosted: Thu Mar 09, 2017 3:16 pm    Post subject: Reply with quote

The heads are finally built up ready to be fitted.

Recut intake and exhaust seats with multiple angles, refaced mounting faces (5thou off each) to remove slight distortion. Cambers measure out at 50cc

New set of exhaust valves and intake valves re-faced, very lightly lapped in to check contact patch.

Exhaust ports slightly modified.

New valve stem oil seals







More soon hopefully


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