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]

Progress is being made, slow, deliberate and educational but progress never the less. So Friday evening I cleaned up all the case bolts by soaking them in simple green then brushing them with a toothbrush and brass wire brush. Also soaked them in Evaporust to get any rust off them and treat them.

Saturday I got the crankshaft assembled with the rods mounted and properly torqued. I spent the rest of the day reading, researching and taking daughter to a birthday party so didn't get to do much more other than set the garage up for assembly. A picture of the assembled crank.

(IMG:http://i273.photobucket.com/albums/jj217/stephenaki/Porsche%20914/CIMG2889.jpg)
Put it together in the basement.

After a posting and some answers I was ready to start assembly...oh wait, I don't have a stand that will fit it. Crap, not only was my stand occupied but it wouldn't work for the Porsche motor. So, after some careful thought I chose the redneck solution and built a stand out of 2x2s.
(IMG:http://i273.photobucket.com/albums/jj217/stephenaki/Porsche%20914/CIMG2891.jpg)
Its actually sitting on oil absorbing material which is set on a furniture mover! Simple and efficient only one problem. I built it for the wrong case half! Dangit! Well, I don't have time to re-build another one so...we move to contingency plan 'b' or what I call the 'ghetto redneck' solution.
(IMG:http://i273.photobucket.com/albums/jj217/stephenaki/Porsche%20914/CIMG2893.jpg)
Just grab the scrap 2x2 wood, turn the original redneck stand around and carefully place things and...wella!

Thus began the insertion of the bearings, lube, etc. OK, lining up the #1 and 4 crank bearings with the dowel rod is easier said than done. After initial assembly with what I thought was a properly lined up bearing I turned the crank. Didn't turn easy, maybe it's just this type of motor? So, post another question about turn resistance, sit, contemplate, get annoyed, go back out and pull the case apart again and start over!

This time I took off the bearings, placed them in the case and then made alignment tics on the bearing and case. This time when the crank went in my son and I lined up the tick marks before putting the case back on. Finger tighten the nuts and bolts, spin the crank. BEAUTY!! Spun much easier, clearly didn't have the bearings lined up to the dowel pin correctly the first go around. Finished torquing the case bolts and nuts and called it a day. Covered the motor with plastic to keep dust out and closed up the garage.

Would have liked to do more but it was 33 degrees here in Stuttgart and my little heater couldn't keep up. Besides the outlet in the garage and the light don't work very well. Landlord paid the lowest bidder to wire the place so it tends to flip the breaker consistently. Well before I close this out, one last picture. My son Alex with his broken wrist; he broke it snowboarding last weekend which kinda set back his basic training date for the air force.
(IMG:http://i273.photobucket.com/albums/jj217/stephenaki/Porsche%20914/CIMG2895.jpg)

Hopefully I can slap on the pistons and cylinders next weekend and finish most of it off. Have to check endplay of the crank but will need to get a dial gauge as the autocraft shop here doesn't have one. I feel better now that I am moving closer to finishing the engine. (IMG:style_emoticons/default/smile.gif)