Steve's unending Progress thread, Air compressor setup recommendations Options

[stephenaki]

OK, this will be the thread that I keep updated as I make progress. I showed up at 0800 at Christoph's place and he was ready for me with a not so glamorous chunk of metal that is my cars heart and soul.

With a little assistance, we loaded it into my Toyota Sienna, not quite I envisioned a mini-van for, and I was headed back to the house. Upon getting home I had to first make coffee then clear out some space in my tiny German garage. So that everyone has a frame of reference to the area that I am working in I have enclosed this lovely 4x6 glossy of my garage in Germany.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747638.1.jpg)

And, for those of you not familiar with the Toyota Sienna, a shot of the engine in the back of the van. There's a lot of room back there for the motor but, it is awkward to get in and out of when loading a motor.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747639.2.jpg)

Now to summarize what was accomplished on the 4th of July, engine brought home, tin, impeller and housing, exhaust, cylinder head and cylinders removed. I had difficulty removing the impeller hub. OK, I didn't get it removed, will need a puller and I don't have one unless anyone can give me any ideas how to get it off without a puller.

Now for the requisite pictures of the motor unmolested.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747639.3.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747640.4.jpg)

Now based on the initial tear down two problems presented it self first the primary issue with a lack of compression...HOLY SHIT!!! Here is what I found.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747641.5.jpg)
(IMG:style_emoticons/default/blink.gif) (IMG:style_emoticons/default/blink.gif) (IMG:style_emoticons/default/blink.gif) (IMG:style_emoticons/default/blink.gif)
Now the cylnder itself was not pitted, it had a build up of corrosion but otherwise in good condition. So I was thinking, maybe I can just clean hone and replace the piston. Well that thought went out the window when I pulled the cylinder directly opposite to it. As you can see by the photo, problem #2.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747642.6.jpg)

More importantly, where did that piece of metal go? An initial look behind the piston shows a knick in the inner portion of the crankcase.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i273.photobucket.com-7987-1268747642.7.jpg)

I will see if there is more significant damage when I split the case; so it begins and were off to a rocket start here at the 914 follies! Stay tuned for the next exciting episode of "never buy a car sight unseen" later in the week! (IMG:style_emoticons/default/happy11.gif)

Gonna go shower and start working on the motor some more. Plan is to have it completely torn down befor the end of this weekend. I will load up some pictures to my photo bucket album and post the link a bit later.

[stephenaki]

OK, so after doing some studying yesterday morning I headed out for the autocraft shop to work on the cylinder heads. (IMG:style_emoticons/default/piratenanner.gif)

The goal was to finish the dismantle and clean up the heads and valves for inspection. First problem, none of the valve compressors they had worked for the cylinder! They didn't have a pneumatic one like I used back state side so after about an hour of screwing around I wound up using a big ass "C" clamp and socket to compress the valve then shake the shit out if to get the keepers to fall off. Typical Army solution to a lack of proper tools. It worked. And for those that are wondering, here is a picture of my solution.
(IMG:http://i273.photobucket.com/albums/jj217/stephenaki/Porsche%20914/CIMG2534.jpg)

Needless to say I screwed around trying to get the spring compressors to work before I did the "C" clamp solution so only got a couple of valve springs and keepers off. I had to go to Ikea with the wife to get some other things so didn't get to stay as long as I wanted too.

So, today, I finished the job. Again, had to do some studying first for my exam. That's always fun translating sentences into Sie, du and Ihr form then making them questions and imperatives in each form. (IMG:style_emoticons/default/blink.gif)

I went back to the autocraft shop around noon and immediately got a socket and "C" clamp to finish the job. So got all the springs and keepers off but none of the valves would come out. Feel around the top and there was an edge built up of metal, not carbon. Well, no sandpaper so I took a fine file and carefully worked off all the edges. Had to do this to every valve.

After about 3 hours of work I got all the valves our and cleaned up and also cleaned up the heads a bit. As you can see by the pictures, no cracks in the heads, this a good thing! They will still need a valve job though just for GP.
(IMG:http://i273.photobucket.com/albums/jj217/stephenaki/Porsche%20914/CIMG2536.jpg)
(IMG:http://i273.photobucket.com/albums/jj217/stephenaki/Porsche%20914/CIMG2539.jpg)
(IMG:http://i273.photobucket.com/albums/jj217/stephenaki/Porsche%20914/CIMG2538.jpg)
(IMG:http://i273.photobucket.com/albums/jj217/stephenaki/Porsche%20914/CIMG2545.jpg)

I don't have any good pictures of the valves but they are in good shape overall and can be re-used. The biggest issue is on one of the heads the valve guide on the bottom was flat for a lack of a better description. If you look closely at the picture you will see what I mean.
(IMG:http://i273.photobucket.com/albums/jj217/stephenaki/Porsche%20914/CIMG2541.jpg)

So, does this mean I will need to replace the guides on this sucker? my assumption is yes but I would like some more experienced input on this. Only one head had this problem, the other head was fine. Play in the valves was very minimal from what I could feel but I didn't have a dial indicator to double check this.

I head back this week after my exam to finish cleaning the crankcase and, when all the Germans come back from vacation, will take the heads and valve's in for cleaning up and a valve job and the crankcase in to be checked for alignment. Will probably take the tin in this week as well and get it cleaned up. I am going to cheap out on the tin and paint it myself once it is completely cleaned and rust treated. When I do the body off restoration I will have it powder coated.

I did get my crankshaft and connecting rods ordered thanks to Smitty's link to the place in California. Once those parts come in I will take everything to get balanced. Slowly making progress; the biggest pain is waiting for parts because even though you can find them here in Deutschland, it is cheaper to buy and ship them from the states. Go figure. Gotta do more studying. (IMG:style_emoticons/default/beer3.gif)