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Thread: Minimal Rebuild. A Bad Idea?

  1. #1

    Minimal Rebuild. A Bad Idea?

    I'm in the process of tearing down my engine at the moment and after looking things over its in very good shape. It was supposedly rebuilt in the late 90's and then driven pretty sparingly although I don't know how many miles were put on it since the odometer has the common broken gear issue. Also, looking at the pieces inside it obviously has been rebuilt although I don't have any documentation on what was actually done. It looks like a new set of Mahle pistons and cylinders were installed with new rings as well as new main and rod bearings and new rod bushings. Overall everything looks to be in really good shape on the bottom end at least. I'm still pulling the heads apart and hopefully those and the cams and rockers will also be just as good.

    With all this, I'm really just thinking of micro polishing the crank and installing new std rod and main bearings. I don't plan to rebuild the rods completely with new bushing simply because the old ones look and measure out at practically new. After that, scuff the cylinders and put on new rings with a new Wrightwood racing gasket kit. Lastly, assuming the heads check out ok at the head shop, clean the up and reuse them along with the cams and rockers.

    Is this a crazy idea? Budget is a big concern but I also don't plan to cut corners however if parts are in very good shape I'd like to use them. The engine is a rock stock 2.2T with few modifications.

    Stretch

  2. #2
    Rebuild generally means to bring an engine back to factory new specifications, if it is already there then of course do not replace parts that meet factory specifications. Seals and such with shelf life will need replacing because of age.
    Have fun!

  3. #3
    Only problem is that if some parts are almost worn out, then you will have to rebuild again soon, so it could be cheaper in the long run to replace them now.
    1971 911S, 2.7RS spec MFI engine, suspension mods, lightened
    Early 911S Registry Member #425

  4. #4
    Yeah, I'm checking parts for wear but at this point everything appears to be within factory specs for a new or nearly new part. I haven't found anything yet that's close to worn out per the book. Obviously there is wear since the engine has been run but at this point it appears to be completely minimal. I know buying or reconditioning all parts would net more miles before overhauling again but I can't imaging it would be very many given the condition. I'm just curious what engine builders would do given this particular engine. I'm rebuilding in my garage and a friends shop and this the first time I've tried rebuilding a 911 engine. The engine ran great but a small crack in the case from a faulty oil galley plug install necessitated a complete disassembly and rebuild. I'm going back to stock except for the oil by pass mod and stud insets. I'm also trying not to spend a fortune getting it back together hence the questions about reusing parts. Thanks for any insight,

    Stretch

  5. #5
    Senior Member Fishcop's Avatar
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    If you're satisfied everything was running fine before hand a part from the case failure (and you've definitely repaired/solved that problem), and all the parts have measured up in-spec; then personally I'd be fine putting it back together.

    The only place I'd be really dilligent to 'rebuild' is the bottom end... If you're happy everything is within specs and tolerances, replace the bearings (reasonably cheap), check the crank (magnaflux or xray) - polish the crank, do the case mods, and button her up - take care on the #8 bearing (use a sealant in addition to the new O-ring). The last thing you want to do is have to split the case again! If you can be satisfied that you have a fresh bottom end, everything else can be worked on without splitting again (not that splitting particularly hard). You'll spend a few $$ doing this, but it's money well spent. The rest of the build is essentially a new seal kit...
    John Forcier
    EarlyS #1987
    1968 911 Race Car "Grun Hilda"
    1969 S/T interpretation "Blau Healer"
    Restoration Saga

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