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Oh, dude, I feel your hurt. I've rebuilt a couple of air-cooled 911 engines, and I now appreciate the simplicity of the great Mezger design.

At the end you mention jogging the crank a bit to see if the piston is perfectly aligned to the access holes. I wonder if you could do that while the circlip tool is in place...keep a little inward pressure on the tool, and jog the crank to feel if the tool seats in all the way. Just a thought.

Keep at it, we're pulling for you!
 

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Discussion Starter #106
Oh, dude, I feel your hurt. I've rebuilt a couple of air-cooled 911 engines, and I now appreciate the simplicity of the great Mezger design.

At the end you mention jogging the crank a bit to see if the piston is perfectly aligned to the access holes. I wonder if you could do that while the circlip tool is in place...keep a little inward pressure on the tool, and jog the crank to feel if the tool seats in all the way. Just a thought.

Keep at it, we're pulling for you!
I missed a crucial step actually. I should have run the scope on through the tool to confirm it was fully engaged before inserting the circlip pusher tool. Jake Raby said it in his video and I completely spaced. Trying again tonight hopefully!
 

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Congrats, great job! I like your idea of putting a chamfer on the edge of the installation tool.

Does anyone know: when the engine is assembled in the factory, do they use this same method? Or is there some magical robotic process to install the pistons and wrist pins?
 
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