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BHZ661
Österreich


Joined: 03 Feb 2015
Posts: 958
Location: Milton Keynes


PostPosted: Tue Jun 21, 2016 2:50 pm    Post subject: Reply with quote

Your certainly getting thro the jobs , those headers look so good shame they are hidden thumbsup
 
  
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RichiRich
Österreich


Joined: 23 Sep 2009
Posts: 997
Location: Luxembourg


PostPosted: Wed Jun 22, 2016 2:44 pm    Post subject: Reply with quote

Subscribed Thumb
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2000 996 Turbo
Speed Yellow / Black

Ex - 2003 996 Carrera 4S
Ex - 1992 964 Turbo X33 (#777)
 
  
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ragpicker
Sepang


Joined: 14 Apr 2013
Posts: 2872
Location: North East England


PostPosted: Wed Jun 29, 2016 10:49 am    Post subject: Reply with quote

Over the past few days I've had a long hard weekend of being head down, ar$e up inside the engine bay trying to make this new air intake fit.

In retrospect there are many, many easier ways of doing this but I was determined to give it a go come what may, and the results confirmed by the butt dyno are very impressive.

So to start, I assembled the parts I thought I needed:
Cayman 987.2 TB (75mm)



987.2 Plenum:


note the separate intake tracts


note the dual AOS breathers


Plus a 987 airbox which had been modified already to remove the baffle:

987 dual hose AOS:


Assorted silicone couplers, reducers and 3inch MAF housings

These reducers on the left are to connect the new (much) larger plenum to the inlet manifolds


I also needed this bit. This is a rubber coupler from the TB to the MAF housing


Right, as you can see, the plenum has a vacuum flap in it which is designed to open and shut at different RPM's on the 987 cars. I thought long and hard about running a slave vacuum hose from the resonance flap actuator to this but as the res flap opens at different RPMs I thought I could end up losing power rather than gaining it. I actually wanted to use the 987 plenum for the dual intake paths as I liked the idea, rather than going with the usual 996 plenum which is a much easier (and less destructive) way of doing it. So, the flap had to go!

Actuator removed:

Flap gone!


First step in doing this mod is to open the engine bay and remove the original TB and plenum. The original TB is 68mm mated to an equally narrow plenum. On the other side there is a 75mm intake path which goes to a postage stamp air filter. This is one of the areas porsche used to choke the boxster to prevent it competing with the 996.

The TB, plenum and main intake pipe is easily removed with a few jubilee clips and some allen bolts.

And this is what is removed (note yet another resonance chamber to keep the noise down!):


This is where things start to be a little more tricky. The 986 airbox is held in place by 3 bolts, 2 on the top and one underneath the car. To remove it you also need to undo the inlet manifold on the left side and move it out of the way.

This is the bolt you need to remove (car in the air on the lift):


Eventually after lots of cursing and grazed arms you end up with this:



Next comes trying to fit the much larger airbox:


As you can see you can't fit the new airbox in without removing the inlet manifold because even with it loose and moved over as in this pic, it simply will not fit. In order to remove the inlet you need to get to a few hoses and clips which are difficult to reach. Best way is to approach the engine through the firewall in the cabin:


After another few hours of carefully removing the inlet, squeezing the airbox in (bending the tabs on the engine bay up and out of the way) and replacing the manifold, it ends up looking like this:


There is a big problem mating the MAF to this due to the shape of the bulk head on the 986 compared to the 987. This gets in the way (image borrowed off t'internet)


At this point I got distracted and ended up going on a 180 mile blat with my friend around the countryside, up to Hartside Cafe in the pennies and back!


Adrenaline pumping after a very high speed drive out, I decided to continue with the project. I test fitted the new plenum and TB only to find that the cable to the new TB wasn't long enough! Some emergency surgery was needed to *ahem* extend it:


So, after much more wrangling, modifying the engine bay lip to accommodate the new TB, and generally getting very angry, I managed to connect the MAF pipe to the TB rubber boot and the new airbox:


With everything bolted down and the intake in place I was so relieved. I think I was about 9 hours in now (not including the drive out), so was so pleased to get it all done! I was on a deadline because the car was due at Revolution in Brighouse for an exhaust bypass mod the morning after.

So... I fire her up.... Huge loud pops, bangs, coughing noises up the inlet manifold, flashing CEL and a smell of fuel! Mad

Turns out that when I had put the fuel rail back in place, the injector for cylinder 6 had missed the hole in the manifold and was spraying fuel all over the top of the engine rather than into the cylinder!

Ok, deep breaths, just unbolt the fuel rail again and re-seat the injector. No biggie.... Until one of the bolts holding the fuel rail in place decided to just spin rather than coming out PC

The offending bolt, in a typically very easily accessible place:


By this time I wasn't thinking straight and gave my friend a call (who is also my indy). He sent me this pic of the manifold and injector rail. He said the captive nut was obviously spinning and I needed to chip away the plastic around it to get a spanner onto it:


So, I removed the passenger seat, knelt down, and poking through the firewall with a small chisel I broke the little bits of plastic off to reveal the nut!


After putting a spanner on it, removing the rail, checking everything and re-fitting properly the installation was finally complete! She fired up first time and settled to a steady idle of 710 rpm. I doused all the connections with brake cleaner without a hint of change in the idle and knew I was good to put the lid on.



Unfortunately, the engine lid no longer fits because the long plenum and then TB are fouling the margin where the lid sits. Its almost like they modified the engine bay on the 987 - who'd have thought!?

Anyway, in for a penny, in for a pound:
Peekaboo!


Whilst I was in there putting the passenger seat back in I thought I'd swap the naff speakers which were in the junk compartment with some much better JBL ones:


So, was it worth it?

Absolutely yes. The car revs much more freely. You can hear the new intake shifting much more air. The flat spot at 5500 rpm has gone and where the surge of torque seemed to die off from here it now keep pulling harder. The intake howl is now almost primal in nature and gives you goosebumps!

I did something similar with my previous 986 but removed the airbox and replaced it with a cone filter. I used a 996 TB and plenum which was so simple to fit it was untrue in comparison (plus needed no alterations to the engine bay or lid). The power difference with that one was noticeable too, but not as much as this. The 987 airbox is a true cold air intake, shielded from the engine, sucking air in through the passenger side vent next to the back wheel and with a filter which must be 10 times the surface area of the 986 one.

The power increase is tangible too. On the exit of a roundabout where I normally road test my mods, before the install I could plant the throttle in 2nd and the rear would squat down and push you forwards. I tried this post-install and the rear end broke free and I needed to add in some counter-steering to prevent me spinning! Now that was unexpected!

So in a nutshell - is it worth it? Yes but its very hard going. If you want 70-80% of the benefit for 40-50% of the effort, use a 996 plenum and TB, and use a cone filter instead.

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996 turbo - slightly modified....
986 S - usually in pieces: http://911uk.com/viewtopic.php?t=112626
 
  
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ragpicker
Sepang


Joined: 14 Apr 2013
Posts: 2872
Location: North East England


PostPosted: Wed Jun 29, 2016 4:37 pm    Post subject: Reply with quote

Yet another update! Got the wheels back from the refurbisher. Went for anthracite in the end:



So immediately put on a couple of coats of this stuff to try to keep them in tip top condition



And then I opened a parcel that had been sitting in my garage for a few days. I thought it was some more silicone tubing.... I forgot I'd ordered this...



Very Happy
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996 turbo - slightly modified....
986 S - usually in pieces: http://911uk.com/viewtopic.php?t=112626
 
  
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Demort
Sepang


Joined: 21 Mar 2015
Posts: 2932
Location: Sussex


PostPosted: Wed Jun 29, 2016 8:10 pm    Post subject: Reply with quote

Now that is a hell of a lot of work .. very impressive .

The wheels .. i love the colour .

The mod to the engine panel .. interesting , no choice but to cut from what i can see .
perhaps some foil backed sound deadening / heat mat over the top but stuck to the engine panel .. im just thinking of the heat transfer onto the foam carpet , might get a little hot.

air box in and out .. hmm .. not something i would look forward to and you can always guarentee if a nut is going to be a problem then it will be the hardest one possible lol.

Now .. young man .. the wireing extension .. crimp connectors ?

Solder , heat shrink and tape up the loom , It has to look nice Smile
( im an Auto electrician so im bound to nag you on that point ! )


Over all .. i have to get paid to do anything like that and your doing it for fun !!

Excellent job , good result and a fine post .. made me smile looking at the pictures and knowing what sort of job you were doing .. keep it up Very Happy

Edit ..

Silly question but i take it the TB cant be rotated 90 degrees to fit under the back part of the car .. does it hit the bodywork there as well ?
 
  
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s70rjw
Monza


Joined: 26 Nov 2014
Posts: 173
Location: York


PostPosted: Wed Jun 29, 2016 8:39 pm    Post subject: Reply with quote

What longevity of Red Rectum like?
 
  
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Dr Who
Newbie


Joined: 07 Apr 2016
Posts: 4



PostPosted: Thu Jun 30, 2016 7:27 am    Post subject: Reply with quote

thumbsup
 
  
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911tom
Barcelona


Joined: 22 May 2012
Posts: 1499
Location: Buckinghamshire


PostPosted: Thu Jun 30, 2016 9:14 am    Post subject: Reply with quote

Another great post Rags. I am really enjoying this thread! So tempted to go out and buy a boxster S.... I am convinced, just need to convince the missus that I need one The Wife

I do agree with Demort Re the use of connector block. They are not great in a car especially on the engine as they can become loose from all the vibrations. Best solution IMO is to crimp and heat shrink. Or as Demort suggests solder. I would heat shrink either way.

Also good choice on the wheel colour. Have you had the exhaust work done now as well?
_________________
996 Turbo - Link to my 3.8L turbo build thread
2011 Cayenne
2009 Ariel Atom 3 Supercharged
350Bhp astra van for work Surprised
 
  
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ragpicker
Sepang


Joined: 14 Apr 2013
Posts: 2872
Location: North East England


PostPosted: Thu Jun 30, 2016 4:16 pm    Post subject: Reply with quote

Cheers guys! I should have known I'd get pulled about the wiring! I only had a few crimps and a bit of chocolate block, so I had to make do. I didn't trust my soldering on something as vital as the throttle, I thought I might lay too much solder down and ***** it up!

Believe me, I tried the TB at every position several times over and this is the way it ended up. Every other orientation led to it sticking up even more.

Tom, you really have to get yourself one and have a tinker. They respond really well to everything you change. I've just been down to Batley and back in it (120 miles) and it just eats the miles. This was its first run out since the new intake and I'm pleased to say it managed the maiden voyage with aplomb!

Am chuffed with the wheels, they're a nice contrast. I was worried they were going to be too dark but the seem to suit the car nicely.





I couldn't go to get the exhaust work done on Monday but I've just spoken to Gareth at Revolution and they are going to squeeze me in in the morning! Can't wait!
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996 turbo - slightly modified....
986 S - usually in pieces: http://911uk.com/viewtopic.php?t=112626
 
  
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ragpicker
Sepang


Joined: 14 Apr 2013
Posts: 2872
Location: North East England


PostPosted: Fri Jul 01, 2016 12:56 pm    Post subject: Reply with quote

Currently sitting at Revolution having the exhaust work done





They also spotted the CV boot held on with a zip tie and have fixed it. I remember when looking back through the documents that the cv boots were actually done here. They must have run out of clips on that day and had to use a zip tie. Sorted FOC today. Excellent service again from Revolution! Very Happy
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996 turbo - slightly modified....
986 S - usually in pieces: http://911uk.com/viewtopic.php?t=112626
 
  
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ragpicker
Sepang


Joined: 14 Apr 2013
Posts: 2872
Location: North East England


PostPosted: Mon Jul 25, 2016 6:44 pm    Post subject: Reply with quote

Well ladies and gelignite, boredom is definitely a dangerous thing....

I've been planning for ages on learning to spray paint so I can just please myself whenever I need some painting doing rather than having to wait for a bodyshop and then fork out for the job. Inspired by homebuiltbyjeff I bought some spray guns, an extractor fan and a few bits and bobs. Since then nothing has really happened. I thought I'd practice on bits and bobs but actually the gun just stayed in the box and has never moved once.

When I bought the boxster there was a patch of ***** lacquer on the bonnet and a few small patches of rust on the passenger wing which really annoyed me, so I tried to touch it up and failed miserably. Since then I've been driving around with an archery target on the bonnet

From anything other than straight on it actually isn't very noticeable, but from square on its an aberration.

Anyway, this weekend I found myself at a loose end so headed into the garage in search of something to do...

First of all I set up an air intake


Then on the opposite side of the bay I set up the extractor. On the front of this is a huge (4sqft) extraction filter)


Then I started taking bits off and sanding..





Then I picked my gun up for the first time and figured out what each bit did. It is a Devilbiss Startingline - a gun for beginner painters. I had previously bought the non-iso paint and lacquer from Jawal in Birmingham. They mixed it according to the paint code.

First coat was terrible. I had the fluid way too open and it was dumping paint and leaving big blobs all over



So I rang my friend (who is a painter) and he told me how to set the gun up - 'dial this in, dial that out and have another go'.

Well, I was flying! Apparently silver is the hardest colour to paint, see what you think..




Then it was time for the lacquer. This is where the limitation of the gun came to light. The fluid tip and spray fan just didn't put enough lacquer out to make it wet, so I had to go very slowly and deliberately to get it wet






Then I left it overnight and started to wet sand it all down (800, then 1500 grit) this morning to remove the orange peel - which I'm told is inevitable when your gun doesn't put much lacquer out.

Following this it was out with the cutting compound and then finishing compound (menzerna) before putting everything back together







I think the colour match is pretty good. The finish isn't perfect, but as its the first time I've ever even held a spray gun I'm really pleased. I'm going to live with it for a bit and then decide if I need to do the rest of the car..... or even go for a different colour completely! Grin

In other news a small split has appeared in the rear plastic window so I've bought a metropol blue hood with glass screen. No doubt thats next weeks instalment.

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986 S - usually in pieces: http://911uk.com/viewtopic.php?t=112626
 
  
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Demort
Sepang


Joined: 21 Mar 2015
Posts: 2932
Location: Sussex


PostPosted: Mon Jul 25, 2016 6:53 pm    Post subject: Reply with quote

Ive been looking forward to your next update ... you haven't disapointed me ..

I think .. Surprised

First time of picking up a gun .. pretty dam good going worship
 
  
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kas750
Paul Ricard


Joined: 31 Mar 2013
Posts: 3163
Location: lancashire

2006 Porsche 911

PostPosted: Mon Jul 25, 2016 8:56 pm    Post subject: Reply with quote

Brill! thumbsup
 
  
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infrasilver
Fast & Furious
Fast & Furious


Joined: 04 Oct 2010
Posts: 6918
Location: East Midlands

2001 Porsche 996 Targa

PostPosted: Mon Jul 25, 2016 9:36 pm    Post subject: Reply with quote

Just caught up with the last three pages of this thread, I remember reading at the start but missed all of the other updates.

Keep up the good work Thumb
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kurlykris
Kyalami


Joined: 30 Jun 2014
Posts: 1757
Location: Warwickshire


PostPosted: Mon Jul 25, 2016 9:41 pm    Post subject: Reply with quote

Is there no end to ragpickers tallents thumbsup

Is that a shadow on the passenger side front wing, or just a glitch in the photo Question

I used to love painting (with rattle cans) when I was younger, it is amazing how good a result you can achieve if you take your time and get the prep right.
Keep up the good work, she looks lovely Thumb
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2006 Boxster S sport chrono
2010 Mercedes E350 AMG Sport

 
  
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ragpicker
Sepang


Joined: 14 Apr 2013
Posts: 2872
Location: North East England


PostPosted: Mon Jul 25, 2016 11:55 pm    Post subject: Reply with quote

Cheers guys!

I can't tell you how much I've enjoyed learning a new skill, and to see it actually looking half decent is even more pleasing!

That patch on the passenger wing is actually a reflection from the van next to it, although there are one or two bits I'm not happy with, fortunately none of them are on that wing>

I might do the wing mirrors metropol blue to match the new hood when it arrives, just for practice. I could always change them back if I don't like it....
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996 turbo - slightly modified....
986 S - usually in pieces: http://911uk.com/viewtopic.php?t=112626
 
  
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HSC911
Magny-Cours


Joined: 23 Jul 2014
Posts: 2560
Location: Bedford


PostPosted: Tue Jul 26, 2016 10:06 am    Post subject: Reply with quote

Great work RP.

Did the seat hard back arrive?

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Homebuiltbyjeff
Trainee


Joined: 26 Mar 2016
Posts: 84



PostPosted: Tue Jul 26, 2016 10:07 am    Post subject: Reply with quote

Great work. It is always more satisfying doing it yourself.

That first photo actually looks like silicone spots, which often occurs when there is still some contamination on the surface. It is not too bad in your case though. A good tip for putting on the first coat of colour is to go a little bit dryer, that way you have less chance of whatever is under neath reacting. Particularly when you have rubbed through an existing paint layer new wet paint can bleed under the edge and "fry up" the paint (which I did a couple of times on my parcel shelf).

Great job though, particularly for your first time. The more you practice the better you will get thumbsup
 
  
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ragpicker
Sepang


Joined: 14 Apr 2013
Posts: 2872
Location: North East England


PostPosted: Tue Jul 26, 2016 10:25 am    Post subject: Reply with quote

Jin - yes it did, thanks very much!

Jeff - yeah its great fun DIYing! I sanded those spots down, re-primered and then started dusting the colour on. The Gunman on youtube recommends dusting metallic colours so the flake stands up more. Looking at it in the sun today it is very bright and metallicky haha.

I'm on the lookout for a good clear coat gun now. Yours seemed to put a lot of clear down nice and wet, what are you using?
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996 turbo - slightly modified....
986 S - usually in pieces: http://911uk.com/viewtopic.php?t=112626
 
  
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Homebuiltbyjeff
Trainee


Joined: 26 Mar 2016
Posts: 84



PostPosted: Tue Jul 26, 2016 11:11 pm    Post subject: Reply with quote

My gun is a cheap copy of an Iwata gun. I used a lot of different guns over the years, and I found the Iwata guns the nicest to use (at least in my opinion).
I have found the "Star" brand good, but the one I have at the moment is "KC Tools". Often it is about the settings, and also having a compressor that can keep the pressure up to the level you need.
 
  
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