Restoration-Mini

Technical Forums => Maintenance and Modifications => Topic started by: MiniDave on May 05, 2020, 12:21:48 PM

Title: 998 Auto Rebuild
Post by: MiniDave on May 05, 2020, 12:21:48 PM
This motor arrived from Boston today, we've been talking about what we're going to do - the brief is to get more HP and keep it smooth and drivable. I'm not going to rebuild the auto transmission at this time, he says it was working perfectly but I will reseal it and try to keep the oil drips to a minimum!  ;D

It arrived in a shipping container I think meant for a V-8, it was laying over on its side and oil was everywhere as you can't really drain the torque converter with the sump, a couple of quarts always stay in there - most of them seem to have found their way out!

I'll tear into it in a week or so and get parts on order and send the block and head off for machine work.

More as it happens.....

When I'm done with this one he wants to send his other one out for some work - it has a 1275 (Japanese spec) and this time he's just going to send the whole car to me. See why I desperately need a bigger shop?  ::) ;D
Title: Re: 998 Auto Rebuild
Post by: jedduh01 on May 05, 2020, 02:23:08 PM
Great task.,  good project but GROSS!   ! from how dirty it is / to a Auto 998...

Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 05, 2020, 02:32:03 PM
Yep, it was pretty messy, but it'll be all shiny and pretty when I'm done with it. It's an A+, BTW.

Looking for any/all performance ideas for this motor, the only thing he wants is a smooth idle and plenty of low end torque.....other than that I can do anything I want within reason. He already got me a  new HS4 so I'm planning on the "stage One " kit with the RC40 exhaust, header, intake and so on.

Looking at 40 over flat top pistons, bigger valves, can't decide whether to go with the Evo1 MiniSpares cam and run regular 1:13 rockers, or go with the Evo2 and 1.5 rockers....of course they're out of the 1.5's right now......the Evo1 can give a lumpy slightly erratic idle in a small engine....I don't think he'd go for that.
Title: Re: 998 Auto Rebuild
Post by: jedduh01 on May 06, 2020, 12:52:05 PM
I personally wouldn't hesitate the .040 - .060 Flat tops + Evo001 Cam. 

After CMU last year, I knew i needed to replace the 2nd gear synchro in my Moke... Engine was coming out + it burned some oil by not being bored previously so its time to tend to the motor too.

I did exactly that. . 040 Flat tops + Evo001 Cam...

going from stock (dished pistons ) and 998 head. (lower comp for sure ) to the Same head and bigger bottom end the end result was NOT Earth Shattering in power making.

   The cam DOES pull better feel better in the upper RPM Ranges.  Perhaps the extra CC"s and compression help a "lump' in the small bore.. but I dont notice it (maybe a tiny tiny bit at cold idle)

My pickup has .060 Flat top 998 -  with a 1275 Head... ,Maifold + single HS4.   Side by side they run Nearly the same.. and with this combo... i would wager these peppy 998's run as good as a poor running 1275.


Moke setup:
Standard 998 head
.040 Flat top pistons
Standard Sintered rockers
HS4 Single carb
Cast manifold
3.44 CWP

Pickup setup:
  .060 Flat tops
 1275 13g16?? Head
Standard sintered rockers
Single HS4
Cooper freeflow manifold
Magic wand gearbox
 3.2 CWP

If its opened up = i agree go for it = only SOOO much you really can do to a 998.... without going nuts nuts...
 
I know ill build another like it for whenever needed, 2 cores in storage.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 06, 2020, 01:07:06 PM
So going to the 1275 head didn't make that much difference over the 998 head? Good to know....

I'm not expecting huge gains, but I was hoping for a little more snap at the bottom end and a little freer running as it revved. I also will put the "Stage one" exhaust and manifold on and ditch the cast iron one...that's supposed to help as much as 20% improvement in both HP and torques?

I'll tear it down next week and see where I'm at.....I was thinking to go ahead and get the 60 over pistons - go for all of it while I'm in there as I know he'll never rebuild it again. It's a car for his wife to drive in town - and they live in Boston, so high speed is not part of the equation.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 07, 2020, 05:04:13 PM
Did the A+ 998 come with flat top pistons? Cause this one has them....

Popped the head off just to see what it looked like.

Plans right now are new, larger valves, a little head work, flat top high compression pistons, Evo1 cam, new springs, new valves, new lifters, bearings, 60 over pistons etc.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 09, 2020, 08:01:37 PM
After looking up the specs via the engine tag, it turns out these A+ 998's did have flat top pistons after all. As part of the rebuild we're considering changing the final drive ratio to a 3.44 as this has a 3:1 for fuel economy, some of them came with a 2.95! This car is strictly an in town car, so he's not concerned with highway RPMs and I think that would help with the stop light grand prix as right now he says it's pretty slow getting away from a light!

I micc'd everything up and am putting together an order to go in to MiniSpares tomorrow, I'll be interested to see both the cost and the time it takes to get parts from them as they claim they're running short staffed and reduced hours right now. I just have a feeling this Brexit thing is going to bite us in the ass on parts at some point, either via reduced availability or increased cost - or both!

I had a heck of a time finding a rear crankshaft seal for this, as the automatic seal is different than the others - I finally found one in Connecticut of all places - at an online store called Sports and Classics......correct part number and description and way cheaper than either Mania or 7Ent - and neither of those places had it in stock anyway. Minispares didn't even list it  - Somerford had a part number listed, but no stock and so on. Spares does sell a gasket kit, but as usual no seals are included. There are a couple of specialty o-rings that I can get from Somerford but on one else seems to stock them and NO ONE carries an oil pump for an automatic - luckily I think this one is fine, there's no scoring inside so I'm planning to just use it.

Pulling the flywheel was interesting too - there are six bolts around the main crankshaft bolt - you remove three of these to install the puller much like on a manual flywheel, but if you take the other three out the torque converter is now junk. The first time I tried to remove it, it pulled the washers up around the heads of the bolts on the puller so I had to go find some heavy duty washers. It's always exciting when one of these comes off cause they usually release with a bang - and this one was no exception!

Once the parts get here I'll send the head and block off to be machined - that could take a while too as the last time I checked the machine shop was backed up 6 weeks....we'll see if they've caught up any.

I'm also going to call for some new parts washer fluid on Monday as this stuff's pretty dirty and I have a lot to clean up.

I found a freeze plug under the torque converter that was clearly leaking oil too - I'm thinking I'll probably just pop it out and clean it then re-install with JB weld for sealer......one of the local brit car shops says they always use it on their cars with no adverse effects.

The bottom pic is what a Mini automatic looks like inside....
Title: Re: 998 Auto Rebuild
Post by: tsumini on May 09, 2020, 10:06:07 PM
Is that a crack between #2 and #3 cylinders?
Title: Re: 998 Auto Rebuild
Post by: ADRay on May 10, 2020, 07:55:34 AM
looks pretty darn clean compared to mine  ;D
Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 10, 2020, 09:02:20 AM
No crack - it would be pretty difficult to get a crack there due to the amount of metal - not saying it's not possible, but I can't think of how that would happen short of a catastrophic failure of some sort.

This engine ran fine, it just was worn down I think....it is very clean inside. No idea how many miles on it but it's clear the owner changed the oil plenty frequently. Once I pull the transmission apart to change the diff we'll see if there's any sludge in the bottom, but I doubt there will be.

This will be strictly a run around the city car - and since the traffic in Boston is brutal, I doubt it will get a ton of miles on it. He just wants to be able to zip around in it, home and back, out for coffee - that sort of thing.
Title: Re: 998 Auto Rebuild
Post by: jeff10049 on May 10, 2020, 03:00:12 PM
Fun project I thought that looked like a crack too glad it's not.

Changing the final drive will probably make all the difference in an auto car.

 Do they have high stall converters for these LOL. Maybe a trans brake and air shifter to go with it that'll fix getting away from the stop light.

Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 10, 2020, 04:59:54 PM
Ha! nah, this is mostly the wife's run about, he just wants to quicken it up a bit since it's unlikely to see the highway other than a quick spurt from one exit to the next around the downtown loop. I would think the combination of 38hp and a tall diff like a 3.1 would make for a pretty dull get away....if I can get it up to 50 hp and with a 3.44 I'm thinking it should be a pretty good difference.....so he'll feel he got his money's worth.

He's already said finish it up so he can send the other one out to me!  77.gif
Title: Re: 998 Auto Rebuild
Post by: jedduh01 on May 11, 2020, 10:39:27 AM
Interested to see the steps and progress to changing the CWP.
  Just the thought of disassembling the Auto sounds intimidating.

I do have a 3.2 in my truck... was a comprimise for a 3.1 vs a 3.4 ... I like it too . Just to throw another thought.

 Are Auto CWP's same ?  No difference. Do you have the 3.44? = I have 2 sets  = need a new home.   Dont buy one.Pay shipping ill send it to you.
 
Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 11, 2020, 11:44:32 AM
Thanks, but I have a couple of 3:44's too, I've changed several out for taller sets and the guys always say "keep it, I have no use for it now".

The last one I did recently, the guy is really excited about the transformation in his car, it's an early Mk1 with a nicely built 1275 so it pulls the 2:76 I put in it just fine. I put a 3.1 in the Inno and my friend John has the same in his, I think it's a good compromise.

As far as I know the diffs are the same, they would have wanted to use as many corporate parts as possible so I'm pretty sure it's the same design, the ratios that were used are the same as the manual gearboxes too.

I haven't pulled an auto apart in decades, so this will practically be all new for me too. Hope I remember how. Last time I did it was to change out a case that had been worn thru on both sides of the final drive by bad rubber u-joints.
Title: Re: 998 Auto Rebuild
Post by: jedduh01 on May 11, 2020, 02:32:37 PM
Regarding Mini Spares:

Instagram posts shows a great shot of all the Shipments to go out the door. Props to the teams for packaging overtime +  Output.  I only wonder about stocks - China / Suppliers output had to have been delayed in some components ... All the UK Stay at home orders just like us have us all shopping and ordering..
  Good to see! 

https://www.instagram.com/p/CADqmrRDagh/?igshid=1lhl22telmduc (https://www.instagram.com/p/CADqmrRDagh/?igshid=1lhl22telmduc)

Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 11, 2020, 02:56:45 PM
A ton of stuff was listed as out of stock, I'm scrambling trying to find some of the stuff I need.

No shortage of business on their end, is there?

I also wonder about DHL, whether they're running short staffed too?
Title: Re: 998 Auto Rebuild
Post by: CooperTune on May 15, 2020, 08:19:36 AM
I love to be wrong, but I have  always thought the auto CWPs are different.

The late and auto A+ 998 engines I have stripped have the 10 to 1 flat top press fit pistons. I like the rods
so I have a large collection of floated 998/1100 con rods.

My 998s are bored .060 O/S balanced with two part S balancer and ultra lite flywheel and back plate. 
Deck block for .005 piston to deck. I use 295 castings with the slightest touch up in ports and bowls.
Hard exhaust seats, O/S intake and exhaust late triple groove valves. Springs to match cam and surface
to reach 10.2 to 1 C/R. The Cooper one pc. header is perfect for just about anything you want to do. My
next one gets twin 1 1/4 s most get a single HIF38. I tend to use 1.3 Cooper S rockers. I have built this
package with SW5, MD266, and MG Metro cam I have not driven any of these but each was as per
customer request and no complaints yet. Steve (CTR)
Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 15, 2020, 10:24:45 AM
That sounds almost exactly what I'm doing, Steve. I think it should make a good package. I haven't torn this transmission down yet, so I don't know for sure, but from what I can see of it the CWP looks the same....and the ratios offered are the same as for the manual transmissions so it makes sense to me they would use the same parts where they can.

Since AP only makes the trans and not the diff, I'm hopeful I can swap it out.

I'm going to dig out my copy of Vizard's book and see if he talks about the 998 heads, if so I'll follow his recommendations...unshroud the intakes at least. I have a "Stage One" kit coming for it too. I wanted to use the Cooper S rockers but everyone is out of stock on them, Maybe I can get some before I'm ready to finish it up.

Any thoughts on using the 1.5 rockers instead ? (Of course, they're out of those too)
Title: Re: 998 Auto Rebuild
Post by: CooperTune on May 17, 2020, 08:47:16 AM
I have always found using 1.5 rockers tends to take away from low end and only add to the top end. I have a NOS set of the KD 1.5
rockers ( yes the pretty ones ) I have yet to find a project for.  Recently I have been thinking lately about returning to Solo 2. While running Solo 2 in the 70s I ran a 1275 Cooper S bored to .060, 13.3 to 1 CR, ST 643 cam, 45 DCOE Weber, SC /CR, 4.35 CWP.  I'm
leaning toward building a 1071 for a new autocross car. I'd love to find a set of S size six inch con rods with a std pin bore. It would
save chopping a big slab off a block. Steve (CTR)
Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 17, 2020, 08:57:47 AM
My MiniSpares order was charged to my card last Tues but I still haven't received a shipping notice from DHL - or any parts for that matter. One week so far since I put the order in.

Of course I found that I had forgotten a few things, fortunately Victoria British is now open again and they show the items in stock and for close to the same price once you factor the exchange rate and shipping.

Wow Steve - 13.3:1 compression ratio? That's significant! With a 4:35 CWP, 1st gear was only to get moving, right? After that you ran the course in 2nd and maybe touched 3rd once in a while on a long course?

I had a 1071 Cooper S way back in the day, it was a sweet little motor!

I found the std ratio forged rockers locally, so I'll go with those instead of the 1.5's.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 17, 2020, 09:56:13 PM
Well Steve, your memory is way better than mine, it does look like the CWP is not interchangeable, just a cursory look tells me the crown wheel is way bigger on this than on a manual. I had to pull the covers off anyway as there was oil and grunge all over this thing and I was always planning to reseal it, new gaskets, axle seals, end cover seals and gaskets and so on, but I don't plan to go any further in the disassembly.

Like I said, it's been decades since I had one of these apart.....maybe 5 of them!

Tomorrow I'll dig out a 3:44 and post a pic to compare the size. It also looks like it takes a very special socket to get the gear off so the pinion could come out and I'd have to have one of those made as I seriously doubt anyone in the US has one to loan.

I got the block and head cleaned up ready to go to the machine shop - I could have taken it all muck covered as they're going to boil it out anyway, but I know I wouldn't want to get one in like that, so fair play to all.

I've got a lot of the side covers cleaned up for the transmichigan, but now I'll have to get the main body in the tank so I can clean it up too and I need to do that in a way that won't get grit in any of the components that are still in there. Should be interesting. I don't want to take the whole thing apart but if I can't get it clean enough and not get crap inside I may be forced to.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 18, 2020, 08:26:44 PM
As Steve pointed out, the diffs are different between manual and auto transmissions, the pic gives a pretty graphic example of HOW different!

When I went to Someford's site they list them and show the ratio for this gearset as 3.27 so not a huge difference to the 3.44 I had hoped to use.

So I'll carry on as we had planned....

Found DHL has my parts and expects to deliver them by Wed end of the day - I found out because they sent me tracking info which showed them going from England to Hong Kong, then to Germany.....seems like a really long way to go around the block to get to Germany (where the DHL hub is) and then to the US.

Went over to Harbor Freight to pick up some more inexpensive wire brushes - they work really well to get the grease and much out of the pores of the aluminum as he wants the transmission case painted too, so I need to get it really clean so the paint will stick.

Went up to Vicky Brits to get some forged rockers - they had 7 and no idea when they would have more. That's the way my whole day went today!
Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 20, 2020, 11:18:33 PM
Forging ahead......a load of parts came in today for the 998 build, tomorrow I'll run the block and head up to the machine shop so they can start on the machine work.
Title: Re: 998 Auto Rebuild
Post by: 94touring on May 20, 2020, 11:27:41 PM
Going with twins or a single carb?
Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 21, 2020, 12:17:13 AM
Single HS4, that's an extra manifold - originally got it for Clancy but he couldn't make twin carbs work on the Moke, so we went with a single carb manifold and an HIF 38 on the Moke.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 22, 2020, 01:28:24 PM
I've been puzzling how to clean up this very nasty gearbox - even tho I have new fluid in the parts washer, it gets dirty pretty quickly, and I didn't want to wash any grit into the transmission - I didn't want to wind up taking it any further apart. There are some seals and o-rings in there that don't come with any of the MiniSpares gasket sets so I didn't want to have to go searching the world for them....especially if it turns out they're NLA. Plus disassembly and re-assembly require some special tools I don't have and would have to make - all of which is unnecessary since we're not going to change the final drive. With an automatic, cleanliness is paramount.

So, after kicking it around a while I came up with a plan - I put the trans in the tank up on a couple of blocks of wood and set it up so most of the liquid run off didn't go inside. I then spent about three to four hours scrubbing the thing down with small wire brushes, scotch pads and small screwdrivers to get into the cracks and crevices.

Then once it was done I took it back out of the parts washer and cleaned the tank thoroughly, even to the point of wiping it out with clean shop towels to make sure I got all the grit out. Once that was done I put it back in the tank, sitting up on the studs on one end. I then poured out about half a gallon of clean solvent that I got from TSC into a bucket and using a basting squirter I rinsed it all down inside and out till everything looked as clean as possible.

It was a ton of work, but I think it came good in the end. Now I can go ahead and put it back together while I wait for the engine machine work to be done. The head work is going to be held up a while as NO one had valve guides except Somerford - I also wanted to put the good forged 1.13 rockers in it and they also were the only ones who had any. So, I managed to get an order for about $150 worth of parts and shipping together in the end.

Before and after pics......
Title: Re: 998 Auto Rebuild
Post by: Willie_B on May 22, 2020, 03:15:36 PM
As good as it's gonna get. Should be after all you did to it.  4.gif
Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 22, 2020, 05:44:57 PM
As long as it works, he said it shifted perfectly before.....

I've run into an interesting snag. In order to put the front drum back in I have to align all the clutch discs inside it as it slides over the inner gear - they tend to move around a bit - should be interesting. I think I found where everything I took out goes back, but the how of it should be fun!  ::)
Title: Re: 998 Auto Rebuild
Post by: jeff10049 on May 27, 2020, 12:57:27 AM
Make sure the drum is all the way down its easy to hang it up on the last disc and think you have it. Lining them up first is not much help you just have to sort of walk it around at a slight angle until each one drops in.  More pressure on one side as you turn.  If that makes any sense.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 27, 2020, 09:58:16 AM
Yeah, so far no joy on this, I can tell the inner most disc is not on the gear, I bet I've had it in and out of there 100 time so far.....frustrating.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 29, 2020, 08:47:25 PM
Spent some time today cleaning, sorting and organizing the hardware and parts for the build. I still have the rockers to do, but the new ones haven't come in yet from Somerford, along with the guides - so nothing will happen on the head till they do.

The block is back at the machine shop, the bores are done and now they'll pop the cam bearings, oil bore plugs and core plugs out and deck the top just enough to clean it up nicely, then boil it out and pop the new cam bearings in, then I can go get it. I don't expect it done for another two weeks yet.

All the parts were supposed to be done at the powdercoaters today, but no call from them either so I guess it will be another week from them too.

I have the new aluminum radiator on the way also, there used to be about 20 of those for sale on Ebay at any given time for $50-60, but I only found one - at $74 - which is still a good buy, but I wonder where all the sellers went?

Title: Re: 998 Auto Rebuild
Post by: MPlayle on May 30, 2020, 11:00:00 AM
I have the new aluminum radiator on the way also, there used to be about 20 of those for sale on Ebay at any given time for $50-60, but I only found one - at $74 - which is still a good buy, but I wonder where all the sellers went?

Since most of those were coming from China, ...

Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 30, 2020, 11:41:39 AM
Yes, but imports from China have not been restricted, only the people......and all of China was not shut down, just the area around Wuhan.....unless all the aluminum radiators and sellers were from Wuhan I don't see the connection.
Title: Re: 998 Auto Rebuild
Post by: MPlayle on May 30, 2020, 12:12:08 PM
It could be the "broad brush" backlash type scenario.  With the general "blame China" and subsequent reactions ("don't buy anything from China if possible"), many of the sellers may have just dropped off rather than continuing to pay listing fees for little to no sales.

Just making a guess.  It could also be as simple as demand dropped off, so sellers dropped listings and have nothing to do with where they were coming from.

Title: Re: 998 Auto Rebuild
Post by: 94touring on May 30, 2020, 02:35:08 PM
I am torn on buying Chinese radiators in the future.  It's one of the rare things they actually got right.  I bet I can have someone local clone them though.
Title: Re: 998 Auto Rebuild
Post by: MPlayle on May 30, 2020, 02:58:04 PM
They are more expensive, but Mini Spares and Mini Sport both carry a few aluminum radiators.

Title: Re: 998 Auto Rebuild
Post by: MiniDave on May 30, 2020, 03:19:11 PM
Is the Fletcher made in England? Or made in China and sold in England?

Seems like it should be easy enough to get one cloned locally, but at what cost? My local rad shop is expensive.....and they are just about the only game left in town. Used to be scores of rad shops, now I know of one.....

Just like machine shops - there used to be half a dozen crankshaft shops in town, now there's one, and it's 45 min north of town.

Getting a block bored is difficult at best, I now know of 2 places - one is in a guy's garage.
Title: Re: 998 Auto Rebuild
Post by: gr8kornholio on May 30, 2020, 10:02:07 PM
I REALLY like the MED one, but itís spendy and currently out of stock. I like a lot of their stuff, Thanks Dan for having the catalog at the BBQ.  :D
Title: Re: 998 Auto Rebuild
Post by: tsumini on May 30, 2020, 10:25:05 PM
Should be enough airplanes laying around to melt down into radiators?
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 08, 2020, 12:52:56 PM
Local automotive paint store is making up a couple of cans of paint for this engine - he wanted 'Resida Green" instead of Morris Green. So, 2 cans of spray color plus 2 cans of spray epoxy primer - $123!

Dan's been telling us how expensive paint and supplies have been getting......
Title: Re: 998 Auto Rebuild
Post by: 94touring on June 09, 2020, 07:39:53 AM
I pay upwards of $200 a quart depending on the color.  It would be a bargain at $123.  Depending on the paint job it's 3 quarts to a gallon.  Then primers and clear coats.  Adds up quickly.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 09, 2020, 11:08:20 AM
This is interesting stuff, it is 2 pack paint in a spray can. How do they do that you ask?

There is a red cap on top of the can, you take that off, turn the can over and put it on the stem there, then push down hard - you've then released the hardener into the paint - you shake it up good and start spraying - cause eventually it will harden off.

I've never used this stuff before, so I will need to get everything I'm going to paint taped off and ready - there is no stopping once you start using this stuff and I don't know how much time you have from the time you add the hardener till it no longer will shoot.....

Dan might have an idea.....

I'll call the paint store and ask them too.
Title: Re: 998 Auto Rebuild
Post by: 94touring on June 09, 2020, 11:14:29 AM
I'm surprised the can doesn't say. 
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 09, 2020, 11:25:31 AM
Actually, it does! Pot life is 8 hours from activation.....tiny print on the side of the can!
Title: Re: 998 Auto Rebuild
Post by: BruceK on June 09, 2020, 04:02:52 PM
Actually, it does! Pot life is 8 hours from activation.....tiny print on the side of the can!

Tiny print because, you know, everybody already knows that!
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 09, 2020, 04:06:32 PM
I was thinking how to get everything set up for this, I think I'll have a lot of tape work to do to keep the paint out of where it doesn't belong, and to get up into all the nooks and crannies and make sure I get a nice even coat on.

Any tips Dan? Wanna come up and shoot an engine and gearbox?

How long after I shoot the epoxy primer do I need to wait before I shoot the color? Hours? Days? weeks?

I also wonder how long before it's hard enough to handle the parts so I can take them back inside. I would like to shoot this stuff in the garage but I would have to build a mini-spray booth and buy a respirator....as it is I'll be lucky if I can find a good mask - so I'm afraid it will have to be done in the back yard. If I wait till late enough in the day I'll have shade, but I hear early in the AM is better as there's little or no wind. Dunno.
Title: Re: 998 Auto Rebuild
Post by: 94touring on June 09, 2020, 04:11:43 PM
30 minutes to an hour from epoxy to paint.  Can probably gives a flash time, but you want it to chemically adhere to each other.  If the epoxy is fully cured the chances of the paint peeling off increases substantially.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 09, 2020, 04:15:27 PM
So, but the time I finish painting enough parts in primer, I'll be heading back to the first thing to start coating the color?

How many coats of primer? Just enough to get good coverage and no more? Multiple thin coats or one good thorough coat? Anything different I need to do to the aluminum to get it to stick, other than clean and grease/oil free?
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 09, 2020, 04:16:46 PM
If the epoxy does get fully cured, can't you just use a scotch pad on it to give it some tooth, then shoot color or are you dead in the water? does the primer dry/cure faster than the color?
Title: Re: 998 Auto Rebuild
Post by: 94touring on June 09, 2020, 04:22:11 PM
Nope, just degrease and spray.  I assume the aluminum isn't a mirror finish. I'd guess 2 light to medium coats, then color.  If you had to wait a day then green scotch brite will do the trick. 
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 09, 2020, 04:26:51 PM
OK, thanks.......

I'm still waiting for the block and head to come back from the machine shops, the other thing I'm trying to decide is whether to build it all up and then paint it, or paint it in chunks and then assemble it.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 11, 2020, 01:22:34 PM
I think I've decided to paint it in chunks, so I can take them out in the back yard and paint them in bits rather than having to build a paint booth in the shop as I will have to lift a completed engine on the hoist and hold it there while I paint. More tape off work but I think I will get a better job when it's done. Painting it all in one chunk would be considerable quicker tho......hmmmm.

Clancy gave me a couple of things as a thank you for the work I've been doing - a set of Cleco's and pliers and an engine hoist device that he makes and sells for Sprites.
Title: Re: 998 Auto Rebuild
Post by: Willie_B on June 11, 2020, 03:18:56 PM
Nice items there. That engine lift attachment looks well made.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 11, 2020, 04:55:09 PM
The loops on top are not quite tall enough for my hook on my hoist to fit, you're supposed to put a bolt thru the loops (front to back) and then hook onto the bolt, but it doesn't fit so I wind up putting a bolt thru the chain on the hoist instead, which works just fine. This is his third design on these, looks like he needs one more!  ;D

I haven't tried to hook onto the loop itself, that might work too......

I don't do a lot of sheet metal work anymore, but the Cleco's are useful for holding things in place while you drill holes and such.

BTW, Cleco is short for the Cleveland Pneumatic Tool Company - who came up with the idea.

Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 15, 2020, 11:14:19 AM
I'm hopeful this week things will get going again on this build......both the cylinder head and block should be back to me by mid week, and the last few parts I ordered 10 days ago now should also be here by Friday - things have really slowed down in the shipping world. I understand that FedEx has warehouses full of packages and UPS is running as much as a month behind on deliveries..... DHL has gone from their usual 3 days from England to me to more than a week. I'll actually be surprised if the parts get here on Friday.

I also had the header ceramic coated, and I'm eager to see how it turns out. I asked the owner if he wanted black, grey or silver and he chose gray as the other two were "too plain", when I got to the coaters they offered black, silver and one other color - NOT grey. So I made an executive decision and it will be "not plain"  77.gif  I think it will look pretty cool actually!

We'll see later this week on it too......

It's hot here - 90+ every day with the typical Kansas humidity -  I'm not spending a lot of time in the shop so I can avoid having to run the A/C and keep the electric bill down a little but when I do go to work for a day it's nice to be able to get it down a bit, just knocking out the humidity helps a bunch and I can run a fan on me to help keep MY temp down. I've become pretty sensitive to heat as I've gotten older, and tend towards heatstroke easily - so there will be no moving to Florida for me!

More as it happens...........
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 15, 2020, 06:20:16 PM
Cylinder head came home today, I cleaned it all up and ran a tap into all the threaded holes. I have all new fasteners for the head and new head bolts once the block comes back. Next I'll need to do a final clean up and get it taped off for paint once the block comes home - I'll have to do the same for the transmission and the rest of the bits.

I need to find someone who can do a finish hone on the rocker bushings - the problem is the shaft size - less that 5/8" - no one has a finish hone that small that I've found yet. I tried using a brake hone I have and while it works - eventually - it takes for freaking ever, and I have 8 of these to do. Plus too and also, I don't know what the finished clearance should be. Too loose and they wear too quickly and rattle, too tight and they wear out or might bind and bend a valve.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 16, 2020, 05:05:37 PM
Block came back today, now I need to get busy cleaning to get ready for paint.

Then a marathon tape off session, set up some tables in the back yard so I can lay stuff out - then start spritzing. Dan, you sure you don't want to take a quick run up to beautiful Overland Park?  :D

Thinking about getting one of those pop up shelters to keep the sun off of me while I paint......they're not expensive and I can use it for shelter at car shows too.
Title: Re: 998 Auto Rebuild
Post by: jedduh01 on June 17, 2020, 09:47:56 AM
Looks great =  that factory yellow + factory red's that came on the heads and blocks are a VERY tough paint!
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 17, 2020, 10:19:24 AM
It sure is, it's already been in the hot tank washer twice to make sure all the debris is out of the cracks and crevices so I'm just going to wipe it down and paint right over it.....if it's stuck on that good the new paint should stick well too.

The weather might have something to do with when I get stuff painted.....we're supposed to get several rainy days - too bad as the last few have been hot and dry - although humid.

The powder coater's just called and said my last bits are ready too, so that should be about it. The last few parts I have coming from Mini Spares won't be needed till about the end of the build, and they're supposed to be here Friday.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 17, 2020, 03:52:46 PM
Interesting, the blue tape marks where the top level of the oil in the crankcase lies. A lot lower in the crankcase that I expected for 5 quarts of oil and a bunch of gears.....
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 17, 2020, 03:57:12 PM
The gearbox is all buttoned up and ready to be painted. I have no idea how I'm going to seal up the end with the gear on it so I can paint, I might pull all those studs back out so I have a flat surface to tape to, then just use plastic I guess? Then I'll set it open side down on some waxed paper and shoot away?

Another way would be to go ahead and build it all together, install the engine on it then paint it, but there's no way I could carry that assembly out to the yard to paint it, and I can't paint it in the garage, so I guess I'll paint it in pieces.

Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 17, 2020, 07:44:07 PM
Picked up the header tonight....the color really changes depending on the light, it's darker than it appears in the pics where it's bolted onto the head - it reminds me of Inconel SS  that's used on F1 headers.

The owner liked it!

The green on the top of the spray can next to the head is what color the engine and trans will be when it's done.

The rest of the powder coated pieces came home today too.
Title: Re: 998 Auto Rebuild
Post by: jeff10049 on June 18, 2020, 12:36:29 AM
Interesting color on the header I think I like it.  Be cool to see it in real life.  Different for sure.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 18, 2020, 10:24:06 AM
It's supposed to rain Friday, so it looks like today and Friday will be clean up and tape off days, then Sat if it's dry I'll set up and get everything ready, then if it's not too hot I'll put some paint on. I also need to mow today before it rains tomorrow.....since I'll be working out in the back yard. I also bought one of those 10X10 pop up tent things to keep the sun off a little - at least off me!  ;D

What effect does higher humidity have - just longer cure times or does it matter on 2 pack paints?

I have three major parts to paint that I want to all be the same color when done, the block, trans and head. Then I have a few smaller parts like the thermostat housing, water pump and drop gears housing that need to match too. Everything else I had powder coated satin black - like the end cover over the torque converter and the timing chain cover, pulleys etc..

Getting the color on will be a major step.....how long should it cure out before I start handling the parts? A week?
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 22, 2020, 07:40:09 PM
Tomorrow is paint day at last, we were supposed to have rain all weekend and today, and didn't get a damn drop - so much for the weather guessers - so I could have done this on Sat and be that much closer to building it up and getting it running. Oh well.....

I got the tent set up in the back yard and tomorrow I'll spray for bugs to keep the nits out of the works, then  set up the block, head, trans, rear housing and a few small bits like the water pump and thermostat housing and spritz away.

Weather is supposed to be cooler tomorrow too and I'm looking forward to that, but it's only going to last one day so I'm taking advantage! Once everything is coated I'll let it sit overnight to cure out a bit then bring it back inside and let it set up for a week or so to really harden off.

Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 23, 2020, 11:07:35 AM
OK, so first a good coat of primer.......then color!
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 23, 2020, 12:11:30 PM
The first can of color did not spray very well, and I only got about 3/4 of the can out before it just quit shooting. So I had to break out the second can - that one worked perfectly and lay down really smooth. I also was able to get into all the little spots I missed with the first coat.

so now, let it cure out, then move all the parts back into the shop and let them harden off for a week. then I can start the assembly process.

With any luck I'll have it up and running in 2 weeks time and he'll have it back before the end of July so he can get it put back into the car.

Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 24, 2020, 10:32:09 AM
This color really varies with the light....

Title: Re: 998 Auto Rebuild
Post by: BruceK on June 24, 2020, 12:50:26 PM
No offense indtended, but the color is close enough to the regular MOWOG green we are all familar with, that it just looks 'off'.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 24, 2020, 01:03:47 PM
Well, the owner likes it - so if he's happy......I think this color is much lighter and less "olivey" but I don't have anything in Mowog green to compare it to.....
Title: Re: 998 Auto Rebuild
Post by: BruceK on June 24, 2020, 01:30:35 PM
Well, the customer is always right.   ;D   The lighter green used on Healey engines is a common BMC alternative engine color.   But whatís the background story on the green paint you painted?
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 24, 2020, 04:12:39 PM
I remember seeing it on VWs and Audis in the 70's, only as a metallic......maybe he saw it there?

I also saw an ad from Crafted Classics (Engine builder in UK) that had a pic of an engine with a light green paint next to one in Mowog green - and he preferred the lighter shade - so maybe he asked them? That's all I know.....

The engine machine shop didn't put the pistons back on the rods, so I ran them back up - maybe they'll be done by Friday.....

Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 25, 2020, 04:56:42 PM
Picked up the pistons today, and a friend gave me the name of a shop that he thought could ream the bushings in the rocker arms for me.

I drove the 20 miles out there today and dropped off the rockers, guy said he'd try and have them ready by tomorrow. This is a really old school machine shop owned by a really old and old school guy. He said he used to have 27 people working for him and now has one - he sang the same old song about not being able to get good help, young guys just aren't reliable and don't have good work ethic and he can't trust their work and so on.......

We exchanged war stories for about half an hour then I left - we'll see if he comes thru for me tomorrow.....I would like to use his shop as he says he can do crank grinds as well as bore blocks and do the hardened seats too - but I question whether he can get things done in a timely manner. He said his crankshaft guy was down to two days a week as that's as long as his knee would let him work - he's scheduled for a replacement as soon as the doctors go back to doing elective surgery again.

Same story I hear all over town - old guys barely keeping the doors open, buried in work they can't get out the door and no help.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 26, 2020, 01:37:27 PM
I picked up the rocker arms this morning, the guy called at 9 am to let me know they were done! That's the last piece of the puzzle on the 998 automatic, now I just need to get down to assembly.  77.gif

We talked a little more about doing some work for me but he said he'd rather see me take it to some of the other shops in town as he just doesn't think he can get my stuff done in a timely manner. I didn't disagree with his assessment, as I walked thru his shop I saw stuff piled up everywhere - he pointed to an old Nash engine that had already been there 2 years waiting for a rebuild. I thanked him thoroughly for the quick service and headed over to the local Brit parts place to pick up a few bits for other jobs and headed home.
Title: Re: 998 Auto Rebuild
Post by: Jimini II on June 26, 2020, 04:01:05 PM
Picked up the pistons today, and a friend gave me the name of a shop that he thought could ream the bushings in the rocker arms for me.

I drove the 20 miles out there today and dropped off the rockers, guy said he'd try and have them ready by tomorrow. This is a really old school machine shop owned by a really old and old school guy. He said he used to have 27 people working for him and now has one - he sang the same old song about not being able to get good help, young guys just aren't reliable and don't have good work ethic and he can't trust their work and so on.......

We exchanged war stories for about half an hour then I left - we'll see if he comes thru for me tomorrow.....I would like to use his shop as he says he can do crank grinds as well as bore blocks and do the hardened seats too - but I question whether he can get things done in a timely manner. He said his crankshaft guy was down to two days a week as that's as long as his knee would let him work - he's scheduled for a replacement as soon as the doctors go back to doing elective surgery again.

Same story I hear all over town - old guys barely keeping the doors open, buried in work they can't get out the door and no help.

Teenagers nowadays don't want to learn a trade they would rather sit behind a computer in air conditioned comfort.
I asked my eight year old Grandson what he wanted to do when he was older his reply was a you tuber or a Football player.
I am glad the machine shop guy was at least honest with you Dave i can't stand shops that BS and lie about time frames.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 28, 2020, 02:22:00 PM
I had tried to assemble the pistons into the block and they did not fit - so I called the guy that did the work and he came over Sat to see what was up. He then took the block and pistons back to his shop and said he'd have it back to me by Monday afternoon.

I guess it got his curiosity up cause he worked on it this morning and brought it back today with an interesting story to tell about what had happened. I had the deck surfaced after he bored it and he said that distorted the top of the cylinders slightly - they were out of round. He was able to clean them up with the rigid hone and it only took about a half thou out to clean it up.

Now of course, I have to completely clean the block up again before I can assemble it....first scrub out the bores with a stiff bristle brush and solvent, then clean them with 409 on another clean brush, then with some penetrating oil, then with regular oil, each time wiping out with a clean white non-shedding cloth. If the white cloth comes out with no black on it - it's good to go.

So, moral of the story, surface the deck BEFORE you bore the cylinders.

The machine shop guy I used to use (who retired right before I took this engine in) would have known this of course, the new guy doesn't.......the good news is the block is fine.
Title: Re: 998 Auto Rebuild
Post by: BruceK on June 28, 2020, 03:39:37 PM
Thatís interesting.  So did the surfacing of the block create some sort of lip at the top of the bore? 
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 28, 2020, 05:33:22 PM
If you've ever seen one of the surfacing machines, it has a large spinning head like a big dinner plate to which the cutter is attached - just the one - the head is large and very heavy so the cutter will cut and not set up a vibration as the wheel turns over it and cuts the deck.

My guess is that as it passes across the deck surface it slightly distorts the bores - makes them slightly out of round....especially at the top. At least that's how he explained it to me......

All I know is that when he brought it back the bores were nicely honed and the pistons seemed to fit perfectly.

Got the pistons and crank installed, now I'm working on setting the cam timing.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 28, 2020, 10:52:28 PM
Got a little more done tonight....

Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 29, 2020, 09:55:29 AM
Well, things were moving along swimmingly till I noticed this......I don't know how I didn't see it before but there it is. That black line is where the rear main seal rides, and it has worn thru the surface hardening of the gear. I've never seen one wear like this before - I've seen them wear a groove in but not this, where the surface is worn off like this.

Anyone have one of these you don't need - for a 998? They're different from a 1275.....

I can get them new from MiniSpares, it's just the time delay waiting for it that annoys me. About all I can do in the meantime is mount the engine to the trans and bolt the head on.....

Oh, A+ 998 only......

Edit - OK, A+ automatics are different than ALL the others, so I found a new one at Somerford and it's on the way.

Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 29, 2020, 09:21:33 PM
Today after I showed this gear to a friend of mine he said he knew a company that could fix it, they do a precision grind down to good metal then build it back up with a chrome process that gives a good hard seal surface again. Cost would be about the same as a new gear and take about two weeks......  ::)

Of course, I already have the new gear coming from Somerford, but it's good to know there are alternatives when needed.

So I got the cam timed in and the head back on, tomorrow I'll bolt it onto the gearbox  then I'm stopped till the gear comes and I can put the back cover on and the torque converter.

I'll need the engine hoist to get it down off so I can put the gearbox up on the bench, then lift the engine onto the transmission.
Title: Re: 998 Auto Rebuild
Post by: tsumini on June 30, 2020, 10:22:26 AM
I would guess the spring in the seal broke thru and rubbed on the land. Doesn't look too deep so plate repair should work.
Your friend is right. In the world of aircraft repair grind and plate is a common repair. If I were to do it I would grind, nickel plate and finish grind especially if there is appreciable thickness. Chrome plate tends to peel off and is  good for thinner build up. Too bad you don't have TWA around anymore and friends there. Unfortunately these repairs to aircraft quality are expensive and make sense only to aircraft parts cost wise. Auto parts could be done to SAE but that would probably still be  uneconomical unless batch run.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on June 30, 2020, 10:46:23 AM
The seal was original as far as I could tell and the spring was still in place, car has 57K kilometers on it and the seal looked and felt viable, I was very surprised to see how deep it had gone - in that you can feel it with a fingernail, or screwdriver.

Someford's online ordering process is so clunky - you place the order, the next day you get an email with the shipping quote, you reply that you want to go ahead with the order, then the next day they send you another email with a link in it, then you go pay for it, THEN they package and ship - it adds at least an extra 3 days to the process and they will only ship FedEx.....who is completely overwhelmed these days with packages.

Remember when FedEx used to advertise "When you absolutely positively have to get there overnight"?

Now it's more like when you absolutely need it to get there someday - maybe......
Title: Re: 998 Auto Rebuild
Post by: tsumini on June 30, 2020, 10:29:44 PM
I avoid somerford for that reason
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 01, 2020, 09:48:52 AM
Not my first choice either, but on some of this odd stuff they are the only game in town.....I'm just happy they had it.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 08, 2020, 04:28:28 PM
Primary gear is supposed to be here on Friday.

In the meantime I got tired of sitting on the couch so I went down to the shop and fiddled about for a bit......added the studs and pins to the bottom of the block and set it on top of the transmission, bolted it down, installed the kickdown lever and linkage and buttoned a few things up......
Title: Re: 998 Auto Rebuild
Post by: MPlayle on July 08, 2020, 04:35:45 PM
How much do we need to admonish you about potentially overdoing it while still recovering from your recent "near death" experience?

Title: Re: 998 Auto Rebuild
Post by: BruceK on July 08, 2020, 05:05:56 PM
How much do we need to admonish you about potentially overdoing it while still recovering from your recent "near death" experience?

Yeah!  Exactly my sentiment too!   Geez it's just a week since you were dead, dude. 
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 08, 2020, 07:29:12 PM
"mostly dead" anyway!

That was less than an hour of work, so no worries.....  77.gif

And I'm done for today, tomorrow will be spent looking for the correct fasteners and laying them out, attaching a few more bits and bobs and so on.

Friday the primary gear is supposed to be here, so then I can add the rear cover, torque converter, oil pump and lines and so on, then it's about ready to go into the engine stand - that will be a red letter day!

I may have a buddy come over first and help me set it into the box again so I can make sure it will fit and look at how I'm going to brace it up.

Once it's in the engine stand I'll fire it up and run in the cam, once I get the timing set and all that, let it cool down overnight and retorque the head, reset the valves and fire it up one more time, then it's ready to go into the box and get shipped off. I'm going to have to check but I think my original estimate of time - given all that was going on - was back to him by the end of July - I'm right on pace to do that.

I may try and turn it over with my big ass 1/2" drill motor on the bench, otherwise it my have to crank an awful lot to fill the torque converter before it pressurizes the bearings.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 09, 2020, 09:44:12 PM
Some more piddling around today, mostly mocking up and finding all the correct fasteners.....tomorrow the primary gear is supposed to arrive, then I can button up the back end and drop it in the engine stand for a fitting and wire up. I still have to clean and paint the alternator and starter before I can hang them on the engine too.
Title: Re: 998 Auto Rebuild
Post by: Willie_B on July 09, 2020, 10:00:08 PM
Looks like you would make a big mess changing the oil filter. Kinda hard to get to it also.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 09, 2020, 10:41:06 PM
I just loosen the cannister and let it all run down into the pan, I don't think it's too hard to get to from below......all the automatics are sideways like this....

I'm planning to run it up with my electric drill to pressurize the oil system since the cannister is pretty big and you can't exactly prefill it - plus you have to fill the torque converter too.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 10, 2020, 04:28:44 PM
The new gear showed up today, so I got it cleaned up and installed on the crank and measured the clearance - it's spot on.

Then I covered the splines so they wouldn't damage the new seal and slid the rear cover on and bolted it all up....note where the dipstick is located.....there also is a nut at the bottom that I need to torque but I haven't figured out how to hold the shaft while I do that. Working on that idea.....I haven't even found a torque spec for it yet but it's either the same as that on the manual or just "gutenteit"!  ;D

Next up the torque converter goes on, but first I need to clean up and locktite the three bolts I took out so I could use the puller to get it off the crank taper.

Then I need to clean up and paint the starter and alternator, then install the dizzy and set the timing. With all that done it will be ready to fill the oil and see if I can crank up oil pressure. Before I do that I'm going to set it in the crate and evaluate where I need to put blocking to keep it from shifting in transit. I may build some simple braces out of EMT to keep it from toppling too.....

IF it fits in my engine stand, then next I'll see if it will run.......more as it happens!
 
Title: Re: 998 Auto Rebuild
Post by: BruceK on July 10, 2020, 09:03:57 PM
It's weird looking at these photos of the automatic and seeing familar things I recognize and then really weird things I've never seen before.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 11, 2020, 10:16:04 AM
I know, right?

Looks like my assumptions were correct, I did have to drill new holes in the mounts as it sits a little higher than a regular manual transmission engine does as the mounts are about 1/2 wider on an automatic subframe. No real matter as I just drilled 4 new holes and bolted it down. The engine steady will be a different matter tho, I will have to rework the engine end of the steady mount since I usually bolt onto the slave cylinder boss - and there is none......going to be an interesting challenge to figure this mount out.

I wound up taking the intake and exhaust header back off - I managed to get it in the engine stand with them on, but could not get them out again without scratching things, so I removed them.

Next up once I've got the engine stand mounts figured out, I'll pop it into the shipping box and see what I need to do there to secure it for the trip home. Then I can build all that stuff at once and have it ready to go.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 13, 2020, 12:22:08 PM
I took the weekend off to rest up a bit, today I sat the engine in the shipping crate to make sure it would fit - and it does - perfectly! In the first pic you can see the base I built to support the engine so it wouldn't flop over like it did when he sent it to me. Now I have to figure out how to strap it down so it won't move in shipment and damage anything.

I will have to leave the intake and exhaust off, but I wanted to make sure the radiator and valve cover wouldn't hit the top of the crate and they do clear, no problem.

EDIT: turns out the intake and exhaust will fit after all, so I will be able to ship them installed. I also turned it 45* so that it's square to the box and it fits that way even better than the way I have it in the pics. Now I'm working out how to strap it down to the base so it won't shift - I was planning to screw some blocks down to keep it from sliding, but I figure I'll also need some straps or brackets to keep it from toppling. It probably won't tip over, but I don't want to take the chance so I'll build some sort of strapping......
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 16, 2020, 11:07:01 AM
I got the engine mounted up in the test bed, all wired and plumbed except for the water temp, I seem to have misplaced the adaptor - I can get one from Vicky Brits so I'll do that this afternoon.

In the one pic you can see my modified engine steady bracket - this engine really wanted to lean over in the test stand so I had to adjust the turnbuckle quite a bit to get it straight.

I also still have the lift bracket Clancy gave me on the engine and I'm using my "paint" valve cover rather than the nice aluminum one I bought for him, because the tin one works with the lift bracket  and the aluminium one doesn't - makes it easier to get it in and out of the stand.

Next up, crank up oil pressure. I used my big half inch drill to try and crank up pressure on the bench but it would barely roll it over, and it got hot pretty quickly - I think the oil pressure came up but it had to fill the oil filter cannister and the torque converter - I put 5 qts in and now it's a quart low. I have to take the red bracket off to get the oil cap off so I can add oil - PITA. At any rate, I don't think it will take much cranking to get pressure on the gauge now, but before I could try it I had to charge up my battery.

Next up..............videos!

Title: Re: 998 Auto Rebuild
Post by: tsumini on July 16, 2020, 05:18:27 PM
I'm curious, how/where do you apply the drill to get oil pressure? I couldn't figure out where/how on mine  so I took the banjo nut off at the pipe to the filter and poured oil in as much as i could then cranked it. 5 second to OP.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 16, 2020, 05:41:19 PM
On the crank bolt, before I bent over the locktab.....and of course the radiator and bracket have to be off too. I have a driver that takes 1/2" drive sockets....
Title: Re: 998 Auto Rebuild
Post by: tsumini on July 16, 2020, 07:31:19 PM
Ok so no flywheel and starter.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 16, 2020, 08:10:01 PM
Well, the starter and flywheel can be on, and I'll use them to pump up pressure next.
Title: Re: 998 Auto Rebuild
Post by: mascher on July 17, 2020, 01:40:02 PM
It may be too late but you can put oil in through the mechanical fuel pump opening.
Kelley
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 17, 2020, 02:17:16 PM
Good point! I just went ahead and took the red lift part off......
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 18, 2020, 04:22:52 PM
It's. A. Live!!!!!!

Just a few seconds runtime as it's blistering hot outside and I don't want to have the door open any longer than necessary - plus I don't have any coolant in it yet - but it runs!

Title: Re: 998 Auto Rebuild
Post by: BruceK on July 18, 2020, 07:51:21 PM
Woo Hoo!!  Congrats
Title: Re: 998 Auto Rebuild
Post by: 94touring on July 18, 2020, 07:51:54 PM
Ready to be shipped out?
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 18, 2020, 08:41:14 PM
Not quite, need to run in the cam, then let it cool overnight and retorque the head and readjust the valves, double check the timing and carb adjustments, then load it in the box and bolt it down. THEN it's ready to ship out.
Title: Re: 998 Auto Rebuild
Post by: 94touring on July 18, 2020, 08:42:52 PM
What's the next project?
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 18, 2020, 08:56:07 PM
Finish the Inno and sell it....
Title: Re: 998 Auto Rebuild
Post by: 94touring on July 18, 2020, 10:01:44 PM
Finish the Inno and sell it....

That will certainly free up shop space!
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 21, 2020, 05:21:55 PM
2nd test run of the 998 automatic. I changed out the carb needle and now it sounds much better. I can't find the adapter that lets me use my mechanical temp gauge so I just screwed in the sender for now, I was going to use my infrared thermometer to keep an eye on the temp but the batteries were dead so I only ran it for about 5 minutes. In the meantime I fixed my temp gun so I can run it longer now. Still some more minor tuning on the carb to do but it's coming around.....since I drained the torque converter, it's taken 8 qts of oil to top it off -I may need another 1/2 qt yet to get it full!

Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 23, 2020, 05:21:35 PM
After re-torqueing the head, resetting the valves, double triple checking the timing and adjusting the carb as best I could, I pulled the 998 auto out of the engine stand and loaded it into the shipping crate on the pallet I made for it out of the one my compressor came on. I cut some 1X8 boards into L shapes and screwed them to the corners of the pallet so the box couldn't shift around on the pallet. I cut up some bits of 2X4 to make blocks so the engine couldn't shift around in the box, then I made some steel brackets out of EMT so that the engine couldn't tumble either, it's as bolted down as I can make it.

I found all the spare bits and boxed them up - new coil and coil wire, exhaust fittings kit, K&N air filter, spare oil filter and quart of oil and the extra heater hose he had asked for, even tho he won't be using the heater on this car as it's strictly a summer car for him.

All I need to do now is gather all the paper work and put it in the box too, then bolt the top on the container and wait for the truck to show up. I'll also put his ratchet straps around the container and pallet so it will be firmly attached......then I'm done.

This has been an interesting project, and it looks like he may be sending more work my way later this year, but before I do anymore of his first I need to get a couple of my own projects finished up!

Title: Re: 998 Auto Rebuild
Post by: Willie_B on July 24, 2020, 08:17:33 AM
Get the Inno finished and sold to a lucky new owner.

Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 25, 2020, 01:27:51 PM
All boxed up and ready to go, just waiting on the truck to come get it. Of course, for that to happen I have to do a major re-arranging of the garage so it will go out the door! No matter, I need to do that anyway.....

18 - 5/16 bolts with nylocks hold the top to the bottom.

All the papers, invoices, build notes etc are in the box along with the extra parts and spares.

Hope it arrives safely!
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 29, 2020, 04:57:44 PM
It's on it's way!
Title: Re: 998 Auto Rebuild
Post by: jedduh01 on July 30, 2020, 10:48:43 AM
Great work!   Cant wait to hear from the owner eventually when its in and running. How much bettter is it with the Mods done vs the ' worn out' unit!

Im sure he will be happy!
Title: Re: 998 Auto Rebuild
Post by: MiniDave on July 30, 2020, 10:55:49 AM
With the bigger valves, +60 pistons, stage 1 exhaust and 266 cam - it HAS to be better - I'm just hopeful that it's better enough to make him think it was worth the money he spent on it! That's the only downside with doing them without the car - you don't get to evaluate the improvements/changes yourself.

It may be a few weeks or more before he gets it installed again - no idea of his work schedule for this car - it was six months after he first contacted me before I saw the motor, and I've had it about 3 months or so....a lot of my delay was due to sublet work - I should be able to turn one of these around in less than 2 months, but there are always delays with machine shops and parts shipments.
Title: Re: 998 Auto Rebuild
Post by: 94touring on July 30, 2020, 11:52:30 AM
Should do well with those items.  At least keep up in traffic well enough.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on August 04, 2020, 11:13:07 AM
Well, the box made it undamaged to Boston, he'll open it up later this afternoon when he gets back to the shop.....
Title: Re: 998 Auto Rebuild
Post by: Willie_B on August 04, 2020, 11:42:41 AM
That was fast.
Title: Re: 998 Auto Rebuild
Post by: MiniDave on August 04, 2020, 12:02:18 PM
Left on Thursday, so 4 business days - either that or it traveled over the weekend, but I agree - pretty quick delivery.

Hope it's undamaged when he takes the top off - I did everything I could to make sure it arrived in good shape.