Hi everyone,
My name is Jason and I am new to the club. I have been looking at a few of the build threads on the forum and thought I would post what my friend and I have been up too lately. My gt4 had been leaking oil from almost everywhere imaginable and the OEM clutch was getting close to needing replacement. The car had around 130,000 Km on it and asides from a downpipe, the car was completely stock down to the original system 10 audio system before the rebuild began.
Tons of oil around the back of the motor
The engine bay was a complete mess from all the oil that had been blown all over the place.
Original clutch with approximately 130,000 km
After spending countless hours in the engine bay with degreaser
Then some undercoating
All was going smoothly with the build until it came time to remove the crank pulley. The first tool we used to hold the pulley broke off the bolts used to fasten it to the pulley. So the next course of action was to drill out the bolts and use an extractor. Easy enough. The problem with that was the extractor bit snapped off inside the broken bolt that we had just drilled out. Finally had to drill and thread 2 new holes in the crank pulley to attach the pulley holder again (this time using stronger screws). This is what the setup looked like to remove the crank bolt. We put a jack under the motor to make sure that we wouldn't damage the threads holding it on the engine stand.
This did the trick
Tearing down the motor
The next big issue was when it came time to remove the head. I only used a 6 point bit instead of the 12 point to take off the head studs. I managed to get all of them off except for 1 of the corner bolts. The bit slipped and I stripped out the head of the bolt
Had to get a set of cobalt bits and drill the head of the bolt until it popped. 
Tear down continued
pistons out
At this point I sent the block and head out to be machined
While waiting for the machine work to be completed a boost, oil pressure and Innovative LC1 wideband were installed
Next came time to sand blast and paint all the oily and rusty parts
And this brings me to where I currently left off on the rebuild. I managed to convince my wife to let me have the 17 inch OZ crono rims that were on her st205. The rims were in rough shape so it was time to sand them down and fix the curb rash on them.
That's where the build is for now. Updates to follow
The stubborn bolts are a familiar story. Encountered a few myself!
Those are some pretty good tips to keep in mind though. Hopefully I wont need to be removing my crank pulley any time soon though. 
The back of the pan was hitting the ARP main studs that were installed. I didn't realize that the aftermarket studs weren't compatable with the stock oil pan. After a quick google search I found out that this was a common issue with the rev 2 motors when fitted with ARP mains. At least it is a simple solution. Just need to make relief's in the stock pan. 
