And my engine project begins
 

Well, for those that don't know I recently got a free s5 that "burned oil" when it was parked. I've been parting that out, and I'm keeping the motor for myself. The motor will be my next project, s5 n/a with some goodies that you will see in due time. Excuse the fact that some of (like half) the pics are a tad blurry. With dirty hands and bad lighting, some of the pics didn't turn out the best. Even though they looked PERFECT on the little viewer on my camera, they came out not so great for some of them.

First the engine was brought home and placed on the stand.

http://home.comcast.net/~rx7projects...-03-2005/1.jpg

http://home.comcast.net/~rx7projects...-03-2005/2.jpg


The next day I began taking the engine apart. Here is the large socket/adapter needed for the flywheel nut.

http://home.comcast.net/~rx7projects...teardown/1.jpg

http://home.comcast.net/~rx7projects...teardown/2.jpg

I'm using an IR impact gun rated to ~350 ft/lbs in reverse at 120psi (I think), however I overdrove it at 145-150psi for a little extra oomph.

http://home.comcast.net/~rx7projects...teardown/3.jpg

Flywheel nut came off without a single problem, I was very happy about that.

http://home.comcast.net/~rx7projects...teardown/4.jpg

http://home.comcast.net/~rx7projects...teardown/5.jpg

However, that god damn 19mm front e-shaft/hub bolt would not BUDGE. I got a torch and proceeded to heating it up for about 30 seconds and it spun right off, luckily.

http://home.comcast.net/~rx7projects...teardown/6.jpg

http://home.comcast.net/~rx7projects...teardown/7.jpg

Front cover off.

http://home.comcast.net/~rx7projects...teardown/8.jpg

Everything detached from under the front cover.

http://home.comcast.net/~rx7projects...teardown/9.jpg

Tension bolts out.

http://home.comcast.net/~rx7projects...eardown/10.jpg

http://home.comcast.net/~rx7projects...eardown/11.jpg

And I begin disassembling.

http://home.comcast.net/~rx7projects...eardown/12.jpg

http://home.comcast.net/~rx7projects...eardown/13.jpg

Hmmm, burning oil.... Think maybe this contributed to it?

http://home.comcast.net/~rx7projects...eardown/14.jpg

Half of the oil control rings just FELL out during disassembling like they were barely even in there, and then this o-ring is... well... effed pretty bad.

More disassembling.

http://home.comcast.net/~rx7projects...eardown/15.jpg

http://home.comcast.net/~rx7projects...eardown/16.jpg

http://home.comcast.net/~rx7projects...eardown/17.jpg

http://home.comcast.net/~rx7projects...eardown/18.jpg

http://home.comcast.net/~rx7projects...eardown/19.jpg

And this is where I gave up for the night.

http://home.comcast.net/~rx7projects...eardown/20.jpg

I ran into a bit of a problem. I couldnt seem to get the last 2 dowel pins out! Now I don't have a dowel pin puller, but on my last build I was still able to get them out without a problem. This time, no dice.

The next mid-day, when I woke up, I started at the engine again. Still couldn't get those damn dowl pins out without a puller. I didn't want to have to buy a dowel pin puller or find one, so I started thinking to myself. All a dowel pin puller is really is just something that threads into them and makes them easy to pull out, right? So I figured a bolt might work just fine. I was going to come on here and ask if anyone know the thread of the down pins, but just for the hell of it I took the bolt I was using the keep the engine stand from rotating out and tried it. Sure enough it worked! I guess I lucked out, but it thread right in and made it very simple to pull them out.

http://home.comcast.net/~rx7projects...eardown/21.jpg

More disassembling.

http://home.comcast.net/~rx7projects...eardown/22.jpg

http://home.comcast.net/~rx7projects...eardown/23.jpg

Mmmm yummy, oil seal failure.

http://home.comcast.net/~rx7projects...eardown/24.jpg

http://home.comcast.net/~rx7projects...eardown/25.jpg

http://home.comcast.net/~rx7projects...eardown/26.jpg

http://home.comcast.net/~rx7projects...eardown/27.jpg

And I'm spent.... That was the end of pulling the engine apart, barely took any time after those dowels finally came out. And here is the mess I left myself.

http://home.comcast.net/~rx7projects...eardown/28.jpg

Organized engine parts.

http://home.comcast.net/~rx7projects...eardown/29.jpg

And everything is all cleaned up and my RX8 can finally have his spot back after spending a couple days outside :)

http://home.comcast.net/~rx7projects...eardown/30.jpg

http://home.comcast.net/~rx7projects...eardown/31.jpg



That's it for now. This is just the beginning, the tear down process. I'll be updating this thread as I go through everything I'm doing. Next will be some porting to the irons, cleaning the housings and inspecting their condition (though they look too worn for the use I want), cleaning the rotors, putting new rotor bearings in, some oil mods, bla bla bla. You'll see as I do them :)

looking good mannnnn,

cool beans, i gotta get ahold of that damn turbo motor

How were the housings and such? You didn't say a damned word about the shape you ass!

That's because they are still dirty and haven't been inspected closely :)

All irons look super! Rear housing looks like too much wear for my liking, front housing is questionable but needs to be cleaned fully to make sure.

Sounds good. A new engine project is always fun. Keep us updated.

nice. whats the other car in the garage?

looks like a porshe maybe?

You are correct. That would be my moms 2001 Boxster, her pride and joy.

^looks like a porsche
EDIT: Damn, too slow typing :(

Anyways, looks cool. Always wanted to do a rotary engine tear down and build up (no, stock is not in my vocabulary for an engine build...) since all i've seen is pictures thus far and still am mesmerised by it. Come to think of it, that's why I got the 7 in the first place...

how do you match your rear port up to the front port when cutting away material? do they have to match? im rebuilding my turbo engine, im doing it cheap but alot of power i hope.

Most people use a template to make sure the the ports are the same. For those that "free hand" their ports (those that are more experienced) I'm not sure exactly what they'd do. If it were me I'd just copy the port onto paper to make sure it is the same front/back.

You're pwning that engine this time. Its hawt.

Yep, this build is going to be better, much better... And much more attention to detail :)

I haven't seen stock ports in a while, they look so tiny!

Haha, I know don't they? They wont be getting too much bigger, though. Just some simple work to them, and possibly a bridge :)

^ :D

TII exhaust sleeves came in the mail just now! All thanks to razorback :D

http://home.comcast.net/~rx7projects...05/sleeves.jpg

What is that yellow guck on the housing? If its oil, what makes it turn into that?

Looks good man! Thanks for the pictures:)

James

Yellow? Which pic are you referring to?