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BBi engine rebuild

Discussion in 'Boxers/TR/M' started by Newman, Nov 10, 2023.

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  1. Newman

    Newman F1 World Champ
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    #1 Newman, Nov 10, 2023
    This engine is pretty original other than the usual EO services over the years. Reliability was the main concern so the goal was to replace the exhaust valves as a preventative measure before a head falls off one, perform the service and clean it up, detail etc.

    Leak down numbers showed 38% past an intake valve (lash setting was fine) and 8-10% being a combo of other valves and ring seal. Oil consumption was another symptom.

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  2. Newman

    Newman F1 World Champ
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    #2 Newman, Nov 10, 2023
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  3. boxerman

    boxerman F1 World Champ
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    #3 boxerman, Nov 10, 2023
    Going to do pistons cams and valves?
     
  4. Steve Magnusson

    Steve Magnusson Two Time F1 World Champ
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    #4 Steve Magnusson, Nov 10, 2023
    How many miles? Was all of the pitting at the "bottom" surface of the cylinders (condensation drops rolling down and sitting at the "bottom")?
     
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  5. Newman

    Newman F1 World Champ
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    #5 Newman, Nov 10, 2023
    Looks like moisture, reminds me of one I did that lived in Hawaii and had a lot of pitting, oil consumption.

    No cams. Doing pistons of course and valves.
     
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  6. turbo-joe

    turbo-joe F1 Veteran

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    #6 turbo-joe, Nov 10, 2023
    and sleeves of course?
     
  7. Newman

    Newman F1 World Champ
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    #7 Newman, Nov 10, 2023
    Boring them oversize not replacing
     
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  8. turbo-joe

    turbo-joe F1 Veteran

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    #8 turbo-joe, Nov 10, 2023
    but for this you have to take them out. I once tried to bore them to oversize ( had at that time the machines). first was working, but the second one started to turn. so I took them all out and put in new ones with std.
    would it not be cheaper to take new ones? labor is the same.

    so put in higher compression pistons?
     
  9. Newman

    Newman F1 World Champ
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    #9 Newman, Nov 11, 2023
    They have to be taken out to properly rebuild the engine but they get put back in and machined in the block with a torque plate and a head gasket to simulate an installed cylinder head. The sleeves change shape when under compression so for the best results they need to be machined under those conditions.

    I'll up the compression ratio a little bit for an increase in torque.
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  10. turbo-joe

    turbo-joe F1 Veteran

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    #10 turbo-joe, Nov 11, 2023
    you are right paul. but I bored the sleeves outside, put them in then and honed them inside.
    good idea with the headgasket and a torque plate ;)
     
  11. Threeofnine

    Threeofnine Formula Junior

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    #11 Threeofnine, Nov 11, 2023
    Out of curiosity, about what would this cost?
     
  12. turbo-joe

    turbo-joe F1 Veteran

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    #12 turbo-joe, Nov 11, 2023
    much much money - but worth every cent when doing right
     
  13. turbo-joe

    turbo-joe F1 Veteran

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    #13 turbo-joe, Nov 11, 2023
    but only with very low "pressure" that the sleeves will not turn
     
  14. Threeofnine

    Threeofnine Formula Junior

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    #14 Threeofnine, Nov 11, 2023
    I would guesstimate $40k? Hopefully it will be a long time before my TR needs an overhaul.
     
  15. 2dinos

    2dinos F1 Rookie

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    #15 2dinos, Nov 11, 2023
    New main bearings? Another 'while you're in there' event?
     
  16. 2dinos

    2dinos F1 Rookie

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    #16 2dinos, Nov 11, 2023
    How do you torque those nuts for the mains? Looks like limited space.
     
  17. 2dinos

    2dinos F1 Rookie

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    #17 2dinos, Nov 11, 2023
    Diff carrier?
     
  18. Newman

    Newman F1 World Champ
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    #18 Newman, Nov 11, 2023
    It already has one of my diffs in it but it was set up incorrectly wherever it was installed. Backlash is .012" and no preload by the feel of it so I'll tighten that up and check the pattern.

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    Here's one I took out of a car, didn't look broken until I undid the left side support and it spread open. I'm making another batch of diffs because I've had some requests.
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    I have a tool I made that's 2" long with a box end wrench end and a 1/2" drive for the torque wrench. It changes the actual torque setting I use because of the 2" added length.
     
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  19. JohnMH

    JohnMH Formula 3

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    #19 JohnMH, Nov 12, 2023
    Agreed - my 78 had rust on the bottom of a few cylinders. It ended up being more cost effective to buy 12 new cylinders at stock bore size and install quality HC pistons. The car is as quick as my TR now.
     
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  20. JohnMH

    JohnMH Formula 3

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    #20 JohnMH, Nov 12, 2023
    Memories. I can vouch for Newman’s differential carrier. Installation in the TR was easy and the pattern was perfect, once Romano sent me a shim. Thanks again to both of you.
     
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  21. 4right

    4right F1 Rookie
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    #21 4right, Nov 12, 2023
    Like the new wall art!
     
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  22. Newman

    Newman F1 World Champ
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    #22 Newman, Nov 16, 2023
    Before pulling the engine I noiced the 2 groove a/c pulley which isn't right for a boxer. Check out the misalignment.

    I need a single groove, if anyone has one shoot me a pm please.

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  23. Newman

    Newman F1 World Champ
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    #23 Newman, Nov 16, 2023
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  24. Rifledriver

    Rifledriver Three Time F1 World Champ

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    #24 Rifledriver, Nov 17, 2023
    If they are not honed with full torque on the torque plates it is pointless. BB cylinders balloon in the middle when under full pressure and will never seal well. One of the reasons for their well known smoke and oil consumption issues. That and the terrible rings and pistons used back then.
     
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  25. Ferraripilot

    Ferraripilot F1 World Champ
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    #25 Ferraripilot, Nov 17, 2023
    Do you remember about how much the distortion was in the middle? Half a thou or so? Just curious for documentation purposes.
     
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