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Dammit
Indianapolis


Joined: 23 Sep 2016
Posts: 2391



PostPosted: Sat Nov 09, 2019 9:14 am    Post subject: Reply with quote

Could you tack the cage in, then offer up the roof panel to check the panel gaps (as it were), and if all is well weld the cage in properly?

Are you going to tie the cage to the B and A pillars?
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infrasilver
Fast & Furious
Fast & Furious


Joined: 04 Oct 2010
Posts: 8507
Location: East Midlands

2001 Porsche 996 Targa

PostPosted: Sat Nov 09, 2019 2:21 pm    Post subject: Reply with quote

MisterCorn wrote:
infrasilver wrote:
I assume you are thinking the chassis may flex while the roof is off and once its back on the skin may not fit so well if the chassis is stiffer with the cage fitted?

Personally I think it should be fine either way?


That was exactly my thinking. I can't imagine it would flex but did consider it a possibility.

MC


It would only be affected if the car is jacked up at any one corner I would have thought?
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7332
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Mon Nov 11, 2019 9:06 am    Post subject: Reply with quote

In a most uncharacteristic burst of efficiency, I came to work this morning to find that the skin installation had been done on Saturday. A very nice job too.
The old sunroof-enabled skin is on eBay.









Cage fitting next, then some actual paint.

MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7332
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed Nov 13, 2019 7:04 am    Post subject: Reply with quote

Doing a bit of tidying up in the garage today, I had taken a spark plug out of the C4 engine for doing some work on measuring chamber volumes. I had thought when I took the plug out that it wasn't in very tight. On refitting it to the engine sure enough the threads are stripped. So it looks like the engine wont' be going back in until one of the heads has been off and this plug thread has been helicoiled. I'll check the others whilst I'm at it but hopefully only one head off for the job.

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Alex
Le Mans
Le Mans


Joined: 06 Mar 2014
Posts: 17144
Location: The Ribble Valley, Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Wed Nov 13, 2019 7:41 am    Post subject: Reply with quote

Can you not helicoil it in situ?




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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7332
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Sat Nov 16, 2019 9:50 pm    Post subject: Reply with quote

I really don't like the idea of doing it in situ, you don't need much swarf to be in the cylinder to mess things up. I'd rather pull the head since the engine is out and it isn't a big job. Not like I need the engine back up and running in a couple of days by the looks of the bodywork.....

In the meantime, I've stripped both doors so that they can be painted. The plan is to run two standard doors for when not using the front cage, and have a pair of fibreglass lightweight doors ready for when the front cage is used and it is on the track. I have bought a pair of 986 Boxster doors to strip for the spare set of internals. This is what is involved in stripping a door. WARNING, if you don't want to strip a door this video is not for you.....


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MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7332
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Thu Nov 21, 2019 7:17 am    Post subject: Reply with quote

I have decided to go with the Time-sert inserts. There probably isn't much difference between them and a helicoil, but I do like the idea of a solid insert rather than a piece of wire where a section could potentially break off. I could do this with the head in place, but given that the cost for a head gasket and a pair of inlet manifold gaskets is not much, I figured I'd rather be sure that there is no swarf in the cylinder when the job is done.

Time-serts don't seem to be readily available in the UK so I have a kit and inserts coming over from the US. Head and inlet gaskets on order from AutoDoc, so time to make a start on the engine.








I took some photos to show the routing of the wiring loom on either side of the engine, then undid the four bolts which hold the intake system to the heads. I undid a couple of brackets from the manifold and the breather connections, then lifted it off the engine. It took about 30 minutes of faffing around in total.

Next I'll turn the engine on the stand so that the 4-6 head is at the top and get ready to remove the head for when the parts get here.

Before I pull the head I will loosen and retorque the other plugs to make sure that they are OK. If one has been damaged I wouldn't be too surprised if others have as well.

MC

Last edited by MisterCorn on Thu Nov 21, 2019 12:03 pm; edited 1 time in total
 
  
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 677



PostPosted: Thu Nov 21, 2019 7:52 am    Post subject: Reply with quote

Good stuff mc. Will you be pulling both heads off and skimming both to make sure compression ratios are the same on both sides?
Will you be raising the CR? Dues anyone bilother with that these days in a bid for a little more grunt?
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7332
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Thu Nov 21, 2019 8:07 am    Post subject: Reply with quote

I will check the head when it is off and only skim if needed, I don't expect this engine to be in for more than a couple of thousand miles at most so I'm not looking to go overboard.

CR is an interesting one, there will be more discussion of this in other threads, there certainly is room for doing things, but I won't be doing them on this engine as it is staying standard. It just needs to keep pushing the car around until the new one is ready.

MC
 
  
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 677



PostPosted: Thu Nov 21, 2019 12:01 pm    Post subject: Reply with quote

I’ve never went down the raising cr route but I wonder what it’d be worth in terms of hp. I’ll be pulling the engine out but don’t really have the space to be splitting it
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7332
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Fri Nov 22, 2019 7:19 am    Post subject: Reply with quote

It will be interesting to find out when we put the new engine in. The CR will be bumped on on that over what the standard engines run.

Camshaft cover, camshafts, and tappet chest removed ready to pull the head, I'll check that the other two spark plus will torque up correctly before I pull it.



MC
 
  
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infrasilver
Fast & Furious
Fast & Furious


Joined: 04 Oct 2010
Posts: 8507
Location: East Midlands

2001 Porsche 996 Targa

PostPosted: Fri Nov 22, 2019 2:32 pm    Post subject: Reply with quote

Nice and clean
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7332
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed Nov 27, 2019 4:07 pm    Post subject: Reply with quote

Timesert kit has arrived. Head removed ready for the operation. I can see the bores for 5 and 6 and they look clean, no signs of any scoring here.









Timesert install next.

MC
 
  
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fot0
Newbie


Joined: 03 Apr 2018
Posts: 35
Location: Thames Valley


PostPosted: Wed Nov 27, 2019 4:51 pm    Post subject: Reply with quote

My 3.4 liners were in great shape too at 100K, although could not check below piston skirts. Be interested to see how my 2nd engine looks when I get some time.

Interested to see how the timesert goes.
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7332
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Thu Nov 28, 2019 7:59 am    Post subject: Reply with quote

Whilst the head was off I thought I'd give the combustion chambers a quick once over. Also had a go with the Timesert kit.







Easy enough to use and does a very nice job from what I can see. Judging by what the bottom looks like when it is finished though, and the amount of swarf which came through, there is no way I would do that on the car.

This was done on a scrap head that had a crack in it. I didn't fancy having a first attempt on the head that I need. I've done a video on the process which I'll post when I get the bits put together.

MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7332
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Fri Nov 29, 2019 10:28 am    Post subject: Reply with quote

More details on fitting the timesert in this video I made.


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MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7332
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Fri Nov 29, 2019 5:23 pm    Post subject: Reply with quote

Parts have arrived to remove the SAI. Fortunately the Porsche tax is not strong on these.



MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7332
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Mon Dec 09, 2019 1:07 pm    Post subject: Reply with quote

Some cleaning up on the block and the head before they go back on with the new gasket. They are looking pretty good here but there are a few bits I'll attack a bit more.





MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7332
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Tue Dec 10, 2019 8:38 am    Post subject: Reply with quote

With the block and the head cleaning finished, I cleaned up the inlet manifold mounting face and dropped the head on with the new gasket, after checking it against the old one to make sure it was the same...



Ready to be torqued up as soon as my angle gauge turns up.

MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7332
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Tue Dec 10, 2019 11:37 am    Post subject: Reply with quote

Cage is being fitted. The rear part went in OK, but clearly something not right at the front. It looks like perhaps the wrongs door bars have been provided?








I've contacted the manufacturer so I'll see what they say.

MC
 
  
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