Robert Lilley wrote:

> To those that want to have more power, but do not want to do a engine swap, but are in need of a rebuild soon...
>
> I am in the process of rebuilding my 88 2.1L Wasserboxer.
>
> I had planned to only do a head gasket repair, but with the death of my transaxle I have decided to do a full engine rebuild with some improvements.
>
> Here are the improvements:
>
>  1) Full engine balance- all rotating parts as a unit.
>  2) Match port the intake runners to the intake opening.(The runners ID was about 2mm smaller than the intake opening ID- to improve flow)
>  3) Clean up the welding on the exhaust system flanges at the head (My new exhaust had welds that restricted flow).
>  4) Matched port the exhaust elbow and the twin pipe inlets. (My ports were off center about 5mm off on one side of port)
>
>  5) CB Performance solid rocker arms.
>  6) CB performance 9mm Rhino rocker swivel feet. (Stock are 10mm but not swiveled)
> (The feet are the same as 911�s and keep the valve stem guide wear down when increasing the lift)
>  7) CB Performance 1.25 Ratio rockers.
>  8) CB Performance cut to fit HP push rods- (to avoid having to shim the rockers
>
> *The 1.25 rockers are the same as FGA is selling.  They cost under @$150 from CB Performance.
>
> I am using cut to fit push rods to eliminate the need for spacers under the rockers and maintain correct geometry.
>
> 9) CB Performance Copper 1.5" exhaust gaskets
> 10) Chip upgrade
> 11) Bosch triple electrode plugs
> 12) Mild porting on Cylinder heads- to clean up rough casting, match all ports to same size
> 13). K&N Air Filter
> 14) Off set grind crank 2mm
> 15) LIFETIME warranty Super Turbo muffler ($58)
> 16) Rebuild heads with combustion chamber re-shaping to improve flow.
> 17) Sanded smooth throttle body casting roughness
> 18) Have the sealing surface of the head anodized to keep from pitting out
> (I have to do more research to see if it is possible and if it will really work)
>
> All of the parts used in the rebuild will be
> 1. German (except where none exist)
> 2. Cleaned 4 times, they will be polished to remove all traces of any foreign matter.

 Wow!!
This rebuild sounds meticulous and well thought out! Can I send you my 2.1????
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Shalom                                                    87 GL
Mark Magee                                            91 Westy
Kemah TX USA                                      96 Suzuki 4WD Sport
John 14:6