Happy New Year and she is almost back on the road again!

Adriasn

New Member
Messages
7
Happy New Year to all on this forum; your posts have been incredibly useful in the engine rebuilt of my 2001 3200GT. I bought the car in 2013 and used it as my daily driver, after having ironed out all electronic glitches, until 2016 when it started to consume more and more engine oil. It seemed a good idea at the time to do an engine rebuild as I read on the forum that spare parts were getting more and more difficult to get. We ( the Indy that maintains it and I) thought we could do this in a couple of months. I love the car and want to keep on driving it for a long time. I have a history in owning Italian exotics so am not afraid to tackle any issues connected to them. In the past we rebuilt the engine of a Ferrari GT4 308 without a problem and that car is still running smooth today. To cut a very long story very short; we were hopelessly optimistic as parts were very difficult to maintain and, once we opened up the engine, a full rebuild, was on the books. The car clearly had suffered from crank end float in the past and had been repaired at some stage, but not very well.... the excessive oil consumption was probably due to the pistons fitting rather loosely in the cilinders.
Anyway, we got pistons from the USA, Clutch from the Czech Republic (three times, the first one was damaged, the second did not fit). Other parts were easier to source, but took a long time. The project came to a screeching halt however when we could not find the all important bearings that lock the crank in the block and should prevent end float. Not available.... In the end I had them made out of bronze and just when they were finished, an original pair arrived... we decided to fit those, so I have a spare set now!
The final set back came when we started to build up the engine again, while fastening the nuts to the studs of the engine shell, the studs came out of the engine shell. Using helicoils did not work, so in the end we needed to find a used engine block. This was sourced, within two weeks, from Germany. The old block will now be converted into a coffee table, I will post photos of that once it is ready.
But the car is now together again and waiting for some cosmetic final touches at the paint shop. After that the roof lining (leather) needs to be reattached to the roof and testing can begin. She will be back on the road again soon!
It has been a labour of love and it would not have been possible without the information on this forum, so thanks to you all,84066CF0-F3AB-446E-A34D-790B7B86E736.jpeg8D309342-A3D9-4A43-8118-C434D008E225.jpeg045B3CDD-DD7A-44B2-A686-088896B6FDEC.jpegBA2B8246-0673-493B-9B99-70AF5785BA0D.jpeg
 

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Scaf

Member
Messages
6,592
Wow, what a journey you have been on!
I have lots of admiration for those able to tackle engine work like this, bet you can’t wait for it all to come together and you are back in the road.
 

Zep

Moderator
Messages
9,294
What a fab looking engine you have there, a real work of art - well worth the effort!
 

safrane

Member
Messages
16,886
Great to read but so sad that parts are such a struggle to find on a car that was still in production in 2002.
 

mjheathcote

Centenary Club
Messages
9,038
Great to read but so sad that parts are such a struggle to find on a car that was still in production in 2002.

Indeed.
But also not good that the aluminium tapped holes failing in the block, including after helicoiling, does indicate real poor quality issues in the casting.
 

Oneball

Member
Messages
11,129
Awesome work.

BMW head bolts are know to pull out on some engines, they can be repaired using steel inserts made by Timesert.
 

alfatwo

Member
Messages
5,517
Indeed.
But also not good that the aluminium tapped holes failing in the block, including after helicoiling, does indicate real poor quality issues in the casting.[/QUOTE

Mike, Its a sign of the engine being badly over heated sometime in its life when the studs pull out, Its not a design fault... it happens all the time on Alfa and Ferrari V6/V8's

They use a strange thread pitch for the head bolts from the factory that isn't available with helical inserts, hence the secondhand block

Dave
 

Adriasn

New Member
Messages
7
Thanks for all your positive reactions. Sourcing parts has indeed been a bit of a quest and it does not reflect well on how Maserati treats its older models... some parts were very easy to find like the water pump, others almost impossible, like the bearings that I had to have made ( and then found some originals). I have attached a pick of those and have heard that several 3200’s are sitting stuck in engine refurbishings because they can not be found. I would be willing to help one of those by selling the custom made ones. (Pic attached). Concerning the problem with the studs in the engine block. I have heard about several theories why this issue may have occurred. One of them is overheating ( and the engine had clearly been thrashed early in its life), the other one that there had been a batch of bad castings. I work for a company that supplies consumables to Foundries and it is true that if aluminium is not thoroughly cleaned of hydrogen during the melting process using the appropriate fluxes, this sort of issue ( brittleness) may occur. If this theory is true I can only surmise that Maserati did not use our product....
Anyway, soon I will be the proud owner of a bespoke coffee table...
Apart from the parts that I mentioned in my first post, much more was replaced, the turbos (which were x-rayed and showed hairline cracks), not the least among them. Some pics attached.
 

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Adriasn

New Member
Messages
7
Sorry, forgot to attach the pic of the bearings... Here it is.
 

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