While I wait for the machinist to finish constructing the fixtures that will hold the case in place for machining, I am putting my 3.2 short stroke motor back together. It started life as a 3.0 in my 1983 SC, and was just tired all the way around.
Although I had the case halves soda blasted and hot tanked, it is still very hard to clean out the oil galleries. It is clear to me that Porsche never paid any thought to rebuilding these motors whatsoever. Here is what you will NOT be doing on my cases:
1. Taking JB weld and coating the outsides of all the aluminum plugs so they don’t leak. Not only is this a totally hack solution to an easily solvable problem, it looks like crap. My case has hex head plugs that can be removed and replaced. A little loctite will keep them in place and leak free.
2. Want to clean out your piston squirters, or verify they work? You need a tool like the (excellent) one from Stomski racing that fits in the case through bolt hole and shoots a jet of air up into the squirter. Alternately, you can rig something up, but it is still a hassle. How about just using removable squirters that unscrew???? Yeah, that’s what I said too.
3. Regardless of what the case looks like from the outside, there is no good way of ensuring the oil galleries are clean and clear without removing the plugs, which is a hassle. Usually you wind up spraying a gallon of carb cleaner through every hole you can see, then say a little prayer, and hope for the best. See point #1.
Also working on a new feature that will make it easy to separate the case halves without hammering or prying. My case should last forever, but if you need to open the motor because you a) dropped something in there b) forgot an oil pump seal, c) forgot to put the chains on the lay shaft and don’t want to use a master link, you’ll be able to split the case easily.
Most of the ideas I came up with were directly borne from building a ton of these engines myself. I hope that shows through in the final product.