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HSC911
Long Beach


Joined: 23 Jul 2014
Posts: 6873
Location: Bedford


PostPosted: Tue Dec 10, 2019 12:11 pm    Post subject: Reply with quote

Cage is cool Cool

Are the bars the wrong way round or upside down Dont know

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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7389
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Tue Dec 10, 2019 7:23 pm    Post subject: Reply with quote

Manufacturer has confirmed they sent the wrong door bars. New ones should be here next week.

MC
 
  
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fot0
Newbie


Joined: 03 Apr 2018
Posts: 38
Location: Thames Valley


PostPosted: Wed Dec 11, 2019 1:24 pm    Post subject: Reply with quote

MisterCorn wrote:


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

MC


I used one and found it to be a faff. Seen engine builders mark the stud bolts and measure angles from 12 o'clock or whatever.
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7389
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed Dec 11, 2019 3:06 pm    Post subject: Reply with quote

I'll hopefully let you know how I get on tomorrow.

Secondary air injection parts removed.







I found that in addition to the two covers I also need a bracket to hold the vacuum reservoir. Less than a fiver from OPC but German stock so need to wait three days for that. The takeoff from the vacuum reservoir which I won't be using for the SAI will be used for the PSE.

Also removed the power steering pump in preparation for going electric.





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infrasilver
Fast & Furious
Fast & Furious


Joined: 04 Oct 2010
Posts: 8529
Location: East Midlands

2001 Porsche 996 Targa

PostPosted: Wed Dec 11, 2019 3:57 pm    Post subject: Reply with quote

fot0 wrote:
MisterCorn wrote:


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

MC


I used one and found it to be a faff. Seen engine builders mark the stud bolts and measure angles from 12 o'clock or whatever.


I have an angle gauge but find it more accurate to mark the bolt/head, the only time I use the gauge is if the angle required is something odd like 70 or 110 etc, anything with 45 or 90 degrees is just a case of marking up where you need your torque wrench to point. I also found the gauge to move a little if you are not careful and you then loose where you turned to already.
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7389
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Thu Dec 12, 2019 7:47 am    Post subject: Reply with quote

It is 60 degrees, then another. I'll mark the bolts and head before I start just in case there is an issue with the gauge. Last thing I want is a problem and have no idea how far it has gone.

Cleaned up the exhaust manifold mounting faces ready for new gaskets.

This is what it looks like before starting.



Here is one I prepared earlier.




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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7389
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Sun Dec 15, 2019 10:01 am    Post subject: Reply with quote

There were signs of possible leakage around the sump, so I took it off and cleaned it ready for refitting. It should be much easier to clean the mounting face on the block and prepare it for sealant with the engine upside down on the stand.



It also confirmed that this engine does have the x51 sump.

MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7389
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Mon Dec 16, 2019 8:51 am    Post subject: Reply with quote

Bracket for mounting the vacuum reservoir on the SAI blanking plate arrived and fitted.





Manifold and head faces cleaned up ready for refitting the manifold.





MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7389
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Mon Dec 16, 2019 12:25 pm    Post subject: Reply with quote

Manifold refitted, various air pipes and wiring refitted.



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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 714



PostPosted: Mon Dec 16, 2019 1:20 pm    Post subject: Reply with quote

Mc did you give any thought to cutting off the power steering pump bracket like ela did? I have to admit I’m not to keen on it though I haven’t looked much at it yet
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7389
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Mon Dec 16, 2019 1:58 pm    Post subject: Reply with quote

Yes, but the throttle body bolts to the top of it, and the AC compressor on the other side, so I didn't bother. Might be different when moving to throttle bodies.

MC
 
  
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 714



PostPosted: Mon Dec 16, 2019 2:21 pm    Post subject: Reply with quote

I’m ripping the air on out so that’s not an issue for me. It would be handy enough to make a bracket to hold the throttle body but I’m in 2 minds.
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7389
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Mon Dec 16, 2019 2:44 pm    Post subject: Reply with quote

If it wasn't for the throttle body I would hack the top part off. This is only a temporary engine to check a dew things, so I'm not fussed.

MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7389
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Tue Dec 17, 2019 8:22 am    Post subject: Reply with quote

Here is a more obvious shot of the PS bracket. You can see that on the left hand side it is used to support the idler/tensioner and the anternator. On the right hand side the AC compressor bolts to it, but there is a large section in the middle which could quite happily be removed. I don't believe for one second that the large section over the top is required for strength.



As I'm fitting the PSE to this car I have fitted the bracket and used the solenoid from the SAI rather than breaking out a new one. I have also tapped in to the same vacuum reservoir rather than fitting the PSE specific one, I don't see the point of running two. If I find that it causes problems doing this I can change it.



When we move to throttle bodies, I will need a second actuator for the flap in the plenum, as the 996 has one, but the 997 GT3 has two. The plan is to use the one which was used for the SAI. Since the standard SAI port has a bracket for the solenoid, as well as a bracket for the vacuum reservoir, I thought I would modify one of these so I can be used for this.





I just need to plug the hole in it to stop a rather nasty exhaust leak. I'll machine up a bit of aluminium to screw in to the hole and have it welded in place. Hole is 7.5mm so I'll tap it out to 8mm and thread some aluminium bar.

MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7389
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Tue Dec 17, 2019 3:33 pm    Post subject: Reply with quote

Waiting for some parts to turn up so done a couple of little jobs.
Replaced bolts in the seats, they looked a bit scruffy.





Turned a piece of bar down to make an aluminium plug for the modified SAI fitting.
Fitting tapped out to M8.





I'm going to seal this in place with the low temp aluminium welding stuff then grind up back to clean it up.

MC
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7389
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed Dec 18, 2019 3:57 pm    Post subject: Reply with quote

Tappet chests, cams, and covers fitted on both sides, cams timed up, sump refitted.
Experimental tappet chest is going on the bank which will house the new sczvenge pump.















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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7389
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed Dec 18, 2019 5:56 pm    Post subject: Reply with quote

First trials on throttle body manifold prototype, it looks like clearance won't be an issue on the AC compressor or alternator, which were concerns.





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Chief
Sepang


Joined: 16 Sep 2010
Posts: 2762
Location: The Middle lands


PostPosted: Wed Dec 18, 2019 6:54 pm    Post subject: Reply with quote

Out engineering Porsche. Like it Grin
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7389
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Thu Dec 19, 2019 7:27 pm    Post subject: Reply with quote

Modified SAI bracket filled in to make it gas tight.





MC
 
  
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 714



PostPosted: Fri Dec 20, 2019 6:37 am    Post subject: Reply with quote

Great stuff. Can you not go with the itb’s separately and use an aftermarket Ecu from the likes of motec or link? I think there’s cheaper options as well. The main problem with going stand alone brains are that you loose all of the factory things like limp mode and whatever else. I don’t think it’d be a major issue to a good mapper though. You don’t have boost your worry about blowing it to bits so how bad can it be?
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