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Thread: The Canary Files: 1969 911T reworked.

  1. #101
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    Cheers Mark!

    Keeping motivated is the key to it all and sharing the journey with your kids is an amazing privilege. Although I will say like you my eldest daughter wants nothing to do with the car what so ever!! But we go 'shopping' to the mall together for our bonding moments!

    I spend way too long thinking about what I need to do before doing what I need to do! It's the intimidation game but that's my process I guess. I make myself do one thing with the car everyday, that maybe cleaning one bolt to editing a video to doing some research online, it keeps things moving even if it's at a snails pace!

    I find these forums a wealth of knowledge and everybody has been very understanding and patient with a first timer! I would like to see more build threads but I think it's the nature of these cars being propelled into the atmosphere in value and prestige that has slowed down the DIY'er taking his or her chainsaw out and going to town But I'm ok with that.

    -Kav.

  2. #102
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    Front Hubs and Rotors

    With the calipers all re-built it's time to swap out the solid brake rotors for the Zimmermann ventilated disks. While I'm in there I'll replace the wheel bearings and change out the studs for the 80mm replacements. Here goes:

    I made a little video of the process:

    <iframe width="853" height="480" src="https://www.youtube.com/embed/WahyHdmohm4" frameborder="0" allow="autoplay; encrypted-media" allowfullscreen></iframe>

    All the new goodies, Zimmermann vented disks, new wheel bearings, Brembo Milano S-caliper etc.

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    The solid rotor and M-caliper

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    Removing the hub is pretty straight forward.

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    Removing the outer wheel bearing, it has some wear and needs replacing

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    The grease seal or oil seal? will get pressed out on my new 20 ton press

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    I found a socket just the right size to push out the outer bearing race.

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    Pressing out the outer race

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    The outer race is out and pressed onto the socket!! I can press that off!

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    The inner race needs to come out next. I will heat up the hub and hammer it out with a punch

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    Being very careful not to gouge the hub! I tap out the inner race, yes it was a PITA!

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  3. #103
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    Pressing out the old wheel studs.

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    Cleaned up the hub in the parts washer then gave it a good blast, I didn't blast the inner surfaces.

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    I made a primitive tool from some an electrical conduit part to push the races into the hub. Outer race first.

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    The outer gets pressed in.

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    Then the inner.

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    Then the 80mm wheel studs go in.

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    I pack the new wheel bearings by hand. It's amazing how much grease you can get in there!

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    The inner wheel bearing in place.

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    I press in the grease seal.

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    I reunite the hub to the new rotor and torque the bolts down to 17ft lbs.

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  4. #104
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    The dust shield hit the Brembo caliper, a little trimming is needed!

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    Now it fits!

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    I'm not going to upgrade the front suspension before the engine rebuild so I will paint the dust shields for now. I will get them plated yellow zinc later on.

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    I heard that white vinegar cleans dirt and rust of metal so I gave it a go on the hardware.

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    I steeped it overnight and gave it a few shakes, it turned out great! I neutralized the acid process with a dip in a baking soda solution. I will have to plate it down the line as it will rust quickly but it will do for now.

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    Dust shield goes on.

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    Hub and rotor back on. I tightened the hub nut enough so that I can still move the washer behind it but there is no play in the hub.

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    All done! Very exciting!

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  5. #105
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    Engine Rebuild Part 1

    Well It's been a long time coming and I was beginning to think I'd never type these words but I've started the engine rebuild!! I have all the parts and the case has been sitting in a box for way too long. I decided to stop thinking about it and just take the leap. I've got the first stage done, the short block complete. Following Wayne's book and the Haynes manual it went a little like this:

    <iframe width="853" height="480" src="https://www.youtube.com/embed/HqTJ2lgVEKY" frameborder="0" allow="autoplay; encrypted-media" allowfullscreen></iframe>

    The case from Ollies machine shop.

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    Align bored back to standard

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    Oil bypass modification by Jay at Jay's precision machine shop

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    Right side of the case mounted on the engine stand.

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    Time certs for the head studs and transmission mounts.

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    Crankshaft and rods all honed, polished with new bushings etc.

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    New 4 rib oil pump from Ebay. Like brand new for only $200! The old magnesium pump was showing signs of wear.

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    Crankshaft mounted to the flywheel ready for the rod install.

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    With new bearings I use some Plastigage and the old rod nuts and bolts to check clearance.

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    All is good between 0.038mm and 0.05mm

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  6. #106
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    New ARP rod bolts and the stretch gauge

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    Measuring the stretch is the way to go (0.009 - 0.0095 is the value) I also checked the torque value too.

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    In an old case the intermediate shaft rode on the surface of the case, Ollies machined it for a standard bearing.

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    Bearings all lubed up

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    Rods are on the crankshaft and the journals are lubed up. New nose bearing too.

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    The crank is back in the case with no drama

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    New SC oil pump with intermediate shaft and new timing chains all ready to go.

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    Installed in the case with a standard bearing.

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    Loctite 574 spread on all the mating surfaces.

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    Through bolts with o-rings torqued down to 25.8 ft lbs

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  7. #107
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    Installed the new head studs with some Loctite 271

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    They all came out to be between 134mm - 135mm

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    Checking the deck

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    Checking the head studs

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    We have a completed short block with flywheel, timing chain ramps and crank pulley etc

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    All very exciting!

    Next is working out the correct clearance from the new high compression pistons to the heads? What is the best way to measure that?

    Cheers!

    -Kav.

  8. #108
    Absolutely awesome documentation, Kav!
    Peter Kane

    '72 911S Targa
    Message Board Co-Moderator - Early 911S Registry #100

  9. #109
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    Quote Originally Posted by 72targa View Post
    Absolutely awesome documentation, Kav!
    Cheers! takes up so much time but it's also fun to do.

    -Kav

  10. #110
    Early S Reg #1395 LongRanger's Avatar
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    Hey, Kav . . .

    . . . nice work. And great work-space, too. Did you do any balancing? . . . rods + pistons, crank, flywheel, etc?



    More, please




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