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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7154
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Tue May 14, 2019 12:34 pm    Post subject: Reply with quote

You keep your eye on eBay and on the forums and wait, then beat me to it Very Happy . Be aware that you will need access to a serious press, around 100 tons, to do the work. I am yet to source one at a sensible price so will be looking to local engineering companies to do that part if I can't get one, it is only a couple of gears I believe. Not something I really want to do TBH, I much rather do it myself, but I'm not looking to pay £6k for a press!!

I will of course be writing up my exploits on here, so you can see what is involved.

MC
 
  
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TurboRob
Trainee


Joined: 18 Feb 2019
Posts: 71



PostPosted: Tue May 14, 2019 1:14 pm    Post subject: Reply with quote

OK thanks, will keep an eye out. Please let me know if you have one or see one you don't want and I'll jump straight on it.

Have access to a press of that magnitude through work so no worries there. Is there a 'rebuild kit' in existence with all the required bearings and shims, etc?
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996.2 C2
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7154
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Tue May 14, 2019 1:25 pm    Post subject: Reply with quote

I have seen some bearing kits, but I would take each one as it goes and see what it needs after taking it apart. It sounds like a fun job to me.

MC
 
  
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NedHan79
Nürburgring


Joined: 08 Nov 2018
Posts: 487



PostPosted: Wed May 15, 2019 12:15 pm    Post subject: Reply with quote

If we already have independent throttle bodies, is there any way to run them separately with their own trumpets? I’m guessing it would need stand alone management. Heat soak would obviously be an issue but it would sound awesome.
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7154
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed May 15, 2019 1:28 pm    Post subject: Reply with quote

Yes there would, the thinking behind the central plenum though is that it can then run an air filter in the same place as usual and have a decent cold air pickup, it will be able to benefit from the torque tuning by using the control flaps in the plenum, and it will look a bit more OEM.
I don't think the management requirements will be very different though as although we could run an AFM, we don't plan on doing so.

MC
 
  
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crash7
Hockenheim


Joined: 28 May 2011
Posts: 638



PostPosted: Wed May 15, 2019 2:50 pm    Post subject: Reply with quote

Martin,

Slightly off-topic, where did you land on brakes? Are you sticking with the Cayenne calipers upfront, or going in a revised direction?
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7154
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed May 15, 2019 3:09 pm    Post subject: Reply with quote

crash7 wrote:
Martin,

Slightly off-topic, where did you land on brakes? Are you sticking with the Cayenne calipers upfront, or going in a revised direction?


I have a set of 380mm front / 350mm rear PCCB disks and 997 GT3 PCCB front calipers which I am working with. Currently waiting for adapter brackets to be made up, so I'll report back when they are finished. I am assuming that the rears will be the same offset as now, otherwise new brackets will be required there as well. I haven't got any rear calipers yet and would want new ones to match the front PCCBs but want to finish the front soon.
These brakes will probably end up on my C2 if the PCCBs fit properly.

MC
 
  
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crash7
Hockenheim


Joined: 28 May 2011
Posts: 638



PostPosted: Wed May 15, 2019 3:27 pm    Post subject: Reply with quote

Thumb I would be interested to see the caliper bracket that you come up with the get the front PCCB calipers to fit to the C2 130mm hole centre knuckle/upright.

Or have you changed the knuckle/upright?
 
  
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NedHan79
Nürburgring


Joined: 08 Nov 2018
Posts: 487



PostPosted: Wed May 15, 2019 7:51 pm    Post subject: Reply with quote

MisterCorn wrote:
Yes there would, the thinking behind the central plenum though is that it can then run an air filter in the same place as usual and have a decent cold air pickup, it will be able to benefit from the torque tuning by using the control flaps in the plenum, and it will look a bit more OEM.
I don't think the management requirements will be very different though as although we could run an AFM, we don't plan on doing so.

MC


Surely if you get rid of the afm you would need aftermarket management. I’ve no experience with Porsche management but I changed it in my Impreza to get more features such as anti lag but more importantly it allowed me to run more boost. Thing is, it was mafless and had to be set up live on the road. I drove and the mapper spent days scaling the fuel, ignition, boost tables along with whatever else. Without an airflow sensor there must be some sort of preset. Like I said I’m no expert but I’d be very interested in the itb route if it was doable at a reasonable cost.
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7154
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed May 15, 2019 7:59 pm    Post subject: Reply with quote

What I mean is that we are planning to run this maffless, so it will need an aftermarket ECU whether we went for a central plenum or not. In theory we could run a MAF and in that case might be able to run the standard ECU, that is something we are currently investigating and if it works I will probably run that on my C2.

MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7154
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed May 15, 2019 8:02 pm    Post subject: Reply with quote

crash7 wrote:
Thumb I would be interested to see the caliper bracket that you come up with the get the front PCCB calipers to fit to the C2 130mm hole centre knuckle/upright.

Or have you changed the knuckle/upright?


No, haven't changed the upright. These are the 997.2 GT2 calipers which have a much larger spacing than the 997.1 or 996 turbo/GT3 calipers, but a smaller piston area than the 6 piston 997.2 turbo calipers so the brake bias won't be affected aversely. With running the 380mm disks there is also more room for a bracket.

MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7154
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Thu May 16, 2019 11:03 am    Post subject: Reply with quote

Implemented CAN bus output of all channels except the rev ranges. This gives a bit more freedom in terms of logging and display of the parameters.



MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7154
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Thu May 16, 2019 4:46 pm    Post subject: Reply with quote

The clip for the cup shift linkage has arrived, unfortunately it won't fit properly as the housing gets in the way. Rather than cut away part of the housing I decided to modify the clip as this is in addition to, not instead of the bracket I made up.







It still hold the metal piece down, it just doesn't apply any backwards pressure to it on one side.

MC
 
  
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steve r
Monza


Joined: 26 Sep 2011
Posts: 215



PostPosted: Fri May 17, 2019 9:19 am    Post subject: Reply with quote

Which part of the housing got in the way of the clip? It fitted without a problem on the 996 housing I tested it on.
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7154
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Fri May 17, 2019 11:11 am    Post subject: Reply with quote

steve r wrote:
Which part of the housing got in the way of the clip? It fitted without a problem on the 996 housing I tested it on.


The ribs in the middle. Only a couple of mm gap.



MC
 
  
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steve r
Monza


Joined: 26 Sep 2011
Posts: 215



PostPosted: Fri May 17, 2019 11:17 am    Post subject: Reply with quote

Mine doesn’t have that rib and neither does the 997 GT3 shifter I have fitted. What car was that one from & what’s it do?
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7154
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Fri May 17, 2019 11:22 am    Post subject: Reply with quote

Part number is 996.424.010.04. I guess they revised the design at some point and removed it. I think this is the original one off my 2001 C4, but to be honest I have so many parts I can't be sure.

MC
 
  
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steve r
Monza


Joined: 26 Sep 2011
Posts: 215



PostPosted: Fri May 17, 2019 12:08 pm    Post subject: Reply with quote

Fair enough, so it could be cut off and the clip used then?

Have you looked at how the Cup cables attach to gearbox bracket? The Cup Car PET shows a different part number than the normal bracket, It’s about £120 so I haven’t ordered one yet until I know if it’s actually required or if the standard one can be used or modified.
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7154
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed May 22, 2019 7:35 am    Post subject: Reply with quote

I have asked my thread on this to be split in to two, to try to keep this mainly about my C4 project rather than other bits I'm working on, there will be some overlap and I've a bit of editing to do to move stuff around. Sorry about this...….


I have spoken with the company who do the machining and there is no problem with getting the chest back on the CNC machine to have it modified. So off it comes....



Old one put back on, haven't bothered torqueing anything up as it won't be started or even turned over until it is back together. I like to keep it assembled as much as possible so I know where the parts are.



One of the coils is cracked so that will be replaced. The others all looked fine so I'll keep them as they are.



Tappet chest needs cleaning up, then ready to go.



MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7154
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed May 22, 2019 7:37 am    Post subject: Reply with quote

The standard engine from my C4 has been taken off the stand...



The Boxster 3.2l engine I have has gone on the stand. I now need to see which components from this:



Are the same as the components on this:



And put any ones which are the same on to this:



The rest of the engine will then be stripped down so that the bottom end can be converted to 3.7l and the heads can go off for porting.

MC
 
  
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