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Chief
Magny-Cours


Joined: 16 Sep 2010
Posts: 2672
Location: The Middle lands


PostPosted: Sat Nov 17, 2018 8:38 am    Post subject: Reply with quote

Martin, this is looking so impressive. I wish I possessed just some of your wiring skills Bandit I’m fretting over fitting heated seats and a decent stereo and there’s you going all NASA Embarassed
Never mind group buy’s. we need to do a group visit and guided tour Cool
1. Chief
2. Kurly Kris
3. Peter S
4. Waz
5.
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6363
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Sat Nov 17, 2018 9:15 am    Post subject: Reply with quote

If anybody is around Eastwood, NG16, you are welcome to pop in. Probably worth waiting a couple of weeks until the suspension and brakes are on. I was told yesterday that the suspension will be ready in 10 days.

MC
 
  
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infrasilver
Fast & Furious
Fast & Furious


Joined: 04 Oct 2010
Posts: 7908
Location: East Midlands

2001 Porsche 996 Targa

PostPosted: Sat Nov 17, 2018 1:39 pm    Post subject: Reply with quote

Chief wrote:
Martin, this is looking so impressive. I wish I possessed just some of your wiring skills Bandit I’m fretting over fitting heated seats and a decent stereo and there’s you going all NASA Embarassed
Never mind group buy’s. we need to do a group visit and guided tour Cool
1. Chief
2. Kurly Kris
3. Peter S
4. Waz
5.


Oi, get to the back of the queue sunshine
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Cunno
Indianapolis


Joined: 13 Dec 2008
Posts: 2260
Location: Nottinghamshire


PostPosted: Sat Nov 17, 2018 8:25 pm    Post subject: Reply with quote

This is a great little vid on a 996 gen1. Really brings home the great value these cars are. I’ve been following the 981 spyder price as I really like them and would make a great euro hoon car but after reading some of the dribble on PH about how these cars are considered high mileage at 8.5k after 2.5 years I’m thinking what’s the point in owning one if you can’t drive it for fear of loosing your shirt in depreciation Which brings me back to the 996 good value and all the car and more than you need for the road, and will cost less than any other Porsche imo to own.
Looking forward to seeing the end product Martin you could be onto a real winner here with your planned mods Thumb off to check the classifieds now Grin


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Present Car: 2006 3.6 Porsche GT3 997(White)
Ex: 2006 3.4 Porsche Cayman S (Silver)
Ex: 2001 2.7 Porsche Boxster (Seal Grey)
 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6363
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Mon Nov 19, 2018 8:12 am    Post subject: Reply with quote

Rear hubs dropped on ready to refit the handbrake mechanism. I have started cleaning up the parts and they should be ready for reassembly tomorrow.



Installation of the centre radiator solenoid is done:



The wires are covered in heatshrink and routed up through a grommet at the top of the wheel well.



The earth will go to the earth point shown in this photo. The white wire needs to route through the fuse box, which will be more of a challenge.



MC
 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6363
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Mon Nov 19, 2018 1:04 pm    Post subject: Reply with quote

Powerflex gearbox mount fitted before I refit the plate on the bottom of the gearbox.



MC
 
  
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Martin996RSR
Spa-Francorchamps


Joined: 08 Dec 2016
Posts: 284



PostPosted: Mon Nov 19, 2018 3:05 pm    Post subject: Reply with quote

Will you keep it 4wd or go with 2wd and save a bit of weight?
 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6363
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Mon Nov 19, 2018 3:40 pm    Post subject: Reply with quote

It has been converted to 2wd. This has been done by removing the propshaft/front diff and driveshafts. I could have chopped the ends off the driveshafts and used those for the ABS sensor wheel but I have changed to using C2 uprights and stubs so that I can run the GT3 type suspension which is not compatible with the 4wd cars due to the odd angle the shock absorbers have to take to avoid the driveshaft. There is still the output flange on the rear of the gearbox but this will just spin around and won’t be an issue. I went this route as the GT3 was based on the C4 chassis as apparently it was stronger. Whether or not there is any truth in the chassis strength thing I don’t know.

MC
 
  
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Griffter
Monza


Joined: 22 May 2016
Posts: 226



PostPosted: Tue Nov 20, 2018 6:23 am    Post subject: Reply with quote

MisterCorn wrote:
Whether or not there is any truth in the chassis strength thing I don’t know.

MC


The chassis is stiffer because of the extra front bulkhead and sheet metal around the front diff area.
 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6363
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Tue Nov 20, 2018 7:36 am    Post subject: Reply with quote

Griffter wrote:
The chassis is stiffer because of the extra front bulkhead and sheet metal around the front diff area.


That's good to know, I suspect that welding/bolting a cage in will make more of a difference though.
I wasn't set on getting a C4, I wasn't set on buying a car at all.... But a C4 was cheaper than a C2, and by the time the spare parts are taken off and sold it makes it cheaper still.

Handbrake mechanism refitted using the manual pictures as a guide to where everything goes, including the retaining spring clips pointing upwards. I can imagine that being a likely fault of handbrakes not working properly if put on the wrong way around. A little bit of copper grease on the moving parts. There is no lever in the car at the moment and with new cables everything is moving very freely so no chance of adjusting anything as the spring on the cable just pushes back on everything.





I will probably hold off fitting the disks and calipers until the suspension is properly fitted as it will give easier access to torque up all of the outer bolts which are just sitting in place in case they need to come out to fit the shock absorbers.

Chassis cross brace and gearbox mount support also fitted after cleaning and painting.





MC
 
  
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Martin996RSR
Spa-Francorchamps


Joined: 08 Dec 2016
Posts: 284



PostPosted: Tue Nov 20, 2018 9:09 am    Post subject: Reply with quote

I'm sure the stronger front bulkhead and a cage will stiffen it up nicely. My car creaks when parking unevenly on a kerb due to stiff suspension and a floppy monocoque.
I think that once the kids are grown up I'm going to put in a roll cage with the strips of metal with lightening holes in, welded to the A and B pillars, and then get it upholstered and nicely padded so I don't put dents in my head with it when i crash.
 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6363
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed Nov 21, 2018 7:31 am    Post subject: Reply with quote

With the rear toe arms not yet fitted there appears to be plenty of space to get the new shock absorbers and springs in so I decided to go ahead and torque up the top arms and make sure that the disks and calipers all fit OK and pipes line up. Looking good so far.







I'm pretty much stuck on the suspension and brakes now until the shocks and springs arrive, hopefully next week.

These are 997 GT3 350mm rear disks running with 996 Turbo rear calipers and 10mm custom spacers and longer bolts. The turbo calipers are required rather than the standard calipers due to the wider disks. Standard 996 turbo brake pipe bracket and short fixed pipe are used.

The larger disks are required to compensate for the larger front disks and increased pad area. I'll post up all the sums at a later date.

MC
 
  
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alex yates
Brands Hatch
Brands Hatch


Joined: 06 Mar 2014
Posts: 14476
Location: The Ribble Valley, Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Wed Nov 21, 2018 8:51 am    Post subject: Reply with quote

Want!
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2000 Manual 996 C4 Arctic Silver Convertible


 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6363
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed Nov 21, 2018 11:52 am    Post subject: Reply with quote

New Behr/Hello condenser fitted. I did try a pattern part which was a bit cheaper, since they are pretty much consumables, but it didn't fit. In the end I got this from Autodoc which was only slightly more expensive.



MC
 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6363
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Thu Nov 22, 2018 7:53 am    Post subject: Reply with quote

Moving on to the interior for a while. The seats and steering wheel are already out, as is the handbrake. Next jobs are to remove the main carpet and dashboard. I have a GT3 RS carpet to be fitted and the dashboard is going to be retrimmed. This is how it looks now……



Removing the gear shift mechanism involves pushing up the cable locking tabs out of the way and then noting the locations of the cables for fitment later.



The rear parts of the cables are held in place by metal clips. Prise them off and then push the two plastic tongues together, the cables then lift out.




Undo the four nuts and the mechanism lifts out.

The gear mechanism will be modified to fit an Alex Yates quickshift which I already have.

Next the two trim pieces at the bottom of the door apertures. The passenger side one requires the rubber to be lifted, two torx bolts to be removed and then lift it upwards to release the clips.


The drivers side one has two plastic overs which are prised off.


Then use a 5mm allen key to undo, but not remove, the screws. The bolts are pretty deep so you can’t do this with a 5mm bit on a screwdriver or 3/8” ratchet.


Then lift it up and remove the two switch contacts, or the cables on an earlier car.


Under the passenger side footwell is a stiff foam cover held in place by two large headed plastic screws. After removing the screws this comes out. Partially removed here.


Front seat belts were removed by undoing the 17mm bolts and taking them out. I'm in two minds as to whether or not to refit them since I will have a harness fitted. Opinions welcomed.

MC
 
  
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coullstar
Barcelona


Joined: 15 Sep 2015
Posts: 1309
Location: Aberdeen/Torphins


PostPosted: Thu Nov 22, 2018 9:16 am    Post subject: Reply with quote

I love reading threads like these.

Your doing what I want to do but through lack of time, funds and getting my finger out haven't done. Your spurring me on to get it done though.
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77szymon
Monza


Joined: 14 Mar 2018
Posts: 156
Location: UK

2003 Porsche 996 Carrera 4S

PostPosted: Thu Nov 22, 2018 10:39 am    Post subject: Reply with quote

Unbelievable job Thumb I was just thinking perhaps as you soon finish this amazing build to keep us entertaining with your set of skills I'm keen to drop my C4S for small makeover. Grin
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2003 Porsche 911 996 c4s
1988 BMW 635csi Highline - waiting for full restoration
1999 BMW e36 328i Cabrio - still not finished project.....
2011 Mercedes S350L
2004 Audi a2 1.4 tdi - I can't stress enough how good these cars are
2012 Mercedes C220 cdi Estate AMG Sport Plus Pack - wife
 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6363
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Thu Nov 22, 2018 11:05 am    Post subject: Reply with quote

77szymon wrote:
Unbelievable job Thumb I was just thinking perhaps as you soon finish this amazing build to keep us entertaining with your set of skills I'm keen to drop my C4S for small makeover. Grin


Much as I would like to, I have the following lined up.

560SEC Service, change electric aerial, fix squeeky heater motor, change air con compressor. Underseal/cavity wax injection.

300SL Service, clean engine bay, change front wheel bearings, fix cigarette lighter socket. Wax cavity injection.

M3 CSL Drop rear subframe and change diff oil seals, new diff oil, change CPV. Clean underneath and underseal/cavity injection

Not to mention the fact that I share the garage with my business partner and he might need to change brake pads or something Dont know

MC
 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6363
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Thu Nov 22, 2018 1:19 pm    Post subject: Reply with quote

Remove the fuse box cover by undoing these four screws.



Remove the dead pedal. This one has been damaged so I'll have to source another one when I screw it back together.



Remove the accelerator pedal by undoing the single screw at the back, then lifting it up about 1/2" at the rear and sliding backwards.


It is held in place by this piece of plastic at the bottom. It comes out easily with the right technique.


Here is the full carpet, compared with the new GT3 RS carpet




The new carpet ha holes in it for the front cage, I'll see if they are I the right place or not. Interior starting to look empty.



MC
 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6363
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Fri Nov 23, 2018 7:42 am    Post subject: Reply with quote

Moving on to removing the dashboard. First job is to remove the passenger airbag. The battery has been disconnected for about 5 months, so no worries there. Underneath the dashboard is a plastic air pipe. These can be pretty stiff, but it just pushes to the left to release the end and then pulls out. I really hate working under dashboards. Having removed the carpet and most of the trim just makes it worse with the sharp edges on everything.






When that is removed there are two 13mm bolts which are removed from above where the ducting was, the airbag then lifts forwards and out. Undo the connector.








The alarm sensor cover is next. The last time I removed one of these I broke the tabs on it, so I was careful to push it further in on the sides this time using an adjustable pliers and a glove to protect the surface. When it was off I noticed that the cover design was different from the earlier one anyway, I think these are probably more robust.





The sensor can be removed and unplugged.



The two air vent trims are removed with a trim removal tool. Once the inside edge gets started them come off relatively easily.







I removed the housing for the alarm sensor and GPS antenna after the trim pieces, just a couple of torx screws. It would be easier to get the vents out if this is removed first (as it tells you to do in the instructions...)

MC
 
  
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