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Jamesx19
Nürburgring


Joined: 10 Jul 2015
Posts: 471
Location: Brighton


PostPosted: Sun May 13, 2018 3:13 pm    Post subject: Reply with quote

Agreed Infrasilver.

A good underbody jet wash ever spring, followed by some waxyoil or dynitrol or similar should keep things preserved for a while. Including suspension bolts and fixings.
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EGTE
Imola


Joined: 06 Jul 2015
Posts: 835



PostPosted: Sun May 13, 2018 3:23 pm    Post subject: Reply with quote

Nice work, James.
 
  
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Marky911
Magny-Cours


Joined: 04 Jun 2009
Posts: 2580



PostPosted: Sun May 13, 2018 4:39 pm    Post subject: Reply with quote

Great work James. The silver areas look ace now. Thumb
 
  
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cobrars
Monza


Joined: 08 Apr 2013
Posts: 191
Location: Newcastle


PostPosted: Mon May 14, 2018 10:09 am    Post subject: Reply with quote

Wow, looks really good up in there now James !!!

Keep up the good work mate !!! Thumb
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Current : Porsche 911 996 C2 Manual With Full Hartech Engine & Gearbox Rebuild

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Car Thread - http://911uk.com/viewtopic.php?t=118834&highlight=
 
  
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Jamesx19
Nürburgring


Joined: 10 Jul 2015
Posts: 471
Location: Brighton


PostPosted: Mon May 14, 2018 3:53 pm    Post subject: Reply with quote

Cheers. Hope it gives others a heads up of what may need looking at on their own cars in the future. Though some will be better.....and some worse.
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Paynewright
Monza


Joined: 17 Apr 2018
Posts: 204
Location: Nr Lutterworth Leics


PostPosted: Mon Jun 11, 2018 8:45 pm    Post subject: Reply with quote

Is the lump back in yet?

Ian
 
  
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Jamesx19
Nürburgring


Joined: 10 Jul 2015
Posts: 471
Location: Brighton


PostPosted: Tue Jun 12, 2018 8:25 pm    Post subject: Reply with quote

Hi Ian, thanks for the interest.

Not yet..... We had to sort some pistons, as the originals apparently have some marks on them that indicate "something" has been through the engine at some point.....

No ideas what that may have been and doesn't, I understand, relate to the reason the engine is being rebuilt. I do have some paperwork in the history file that showed a cylinder head had been off in 2005 ish, but nothing to say why.

Pistons may have been reusable, but decided that I should fit new ones.

Hopefully will be back together soon and in before July fingers crossed.

The chassis now has more wax in it and under it than Westminster Cathedral.

Cheers
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Jamesx19
Nürburgring


Joined: 10 Jul 2015
Posts: 471
Location: Brighton


PostPosted: Tue Jul 03, 2018 3:25 pm    Post subject: Reply with quote

Got a parcel delivered yesterday.......







From Hartech, all nicely wrapped up............









And after a few excited minutes:







Just got to get on and put it back together and get it fitted in.




Old exhaust manifolds have seen better days:




Interesting seeing the restriction in the throats of the manifold runners, caused mostly by weld.....











Compared with new ones going on:






Will keep you updated on progress

Cheers Jim
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rdodger
Monza


Joined: 08 Apr 2018
Posts: 191
Location: Cheshire


PostPosted: Tue Jul 03, 2018 3:42 pm    Post subject: Reply with quote

Now that's what I call a parcel!

Looking forward to seeing the install with the shiny parts!
 
  
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Dammit
Indianapolis


Joined: 23 Sep 2016
Posts: 2305



PostPosted: Tue Jul 03, 2018 4:33 pm    Post subject: Reply with quote

+1
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deMort
Dijon


Joined: 21 Mar 2015
Posts: 7270
Location: Brighton


PostPosted: Tue Jul 03, 2018 7:41 pm    Post subject: Reply with quote

Get that little tool box of yours working and rebuild her young man Very Happy
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Thank you all so Very much .

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coullstar
Albert Park


Joined: 15 Sep 2015
Posts: 1594
Location: Aberdeen/Torphins


PostPosted: Tue Jul 03, 2018 8:16 pm    Post subject: Reply with quote

I'd be in there until it was back in. That was quite quick though for the rebuild.
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Jamesx19
Nürburgring


Joined: 10 Jul 2015
Posts: 471
Location: Brighton


PostPosted: Wed Jul 04, 2018 8:50 pm    Post subject: Reply with quote

Thanks for the comments chaps,

Was a bit longer than expected. It would have been back early June, but it appears "Something" had been through the engine at some point in the past. Marking the piston crowns, but not causing any damage to the bores or piston skirts..... no ideas. But the engine is 20 years old so lots could have happened in the past.





Piston skirts have the Ferrous coating later changed to plastic in later cars. Look as good as new!





Although the marking didn't affect the engine usability or performance, (Still running very well before being stripped and sent for the rebuild) I went for some new ones, choosing to use six new forged pistons from Wossner. These appear to be a good quality forged piston made from 4032 alloy and have tight piston to bore clearance of 0.05 mm.

Cost of new Porsche Mahle ones didn't stack up. I'm lead to believe that production tolerances from new are "variable".

Weight of the pistons is broadly similar I think. Wossner quotes 398 grams, but not sure if that includes gudgon pins and piston rings? The Porsche Mahle ones, together with gudgon pins and piston rings are 544 grams. I weighed one of my Mahle ones without the gudgon pin and it came in at 425 grams.

Anyway, getting hold of the new pistons caused a slight delay.

Spec is as follows:

6 x new Nikasil plated alloy cylinder liners + modify the engine casings.
6 x new forged pistons
1 x Larger sprocket and bearing on a modified IMS
Cylinderhead overhauls inc skim and cut the seats, new valve seals etc
All timing chains, rails, and tensioners changed for new,
ARP big end rod bolts
New Low temp thermostat and new oil pump spring (my request)
New bearings throughout - of course.

I broke out the "little toolkit" (Demort Smile ) and started getting it back together this evening.....





The exhaust manifolds are being put back on with Stainless steel (304 as 316 is not as strong) studs. Marine grade washer including a spring washer locking system. Brass nuts.








Comparison with new and old manifolds. The entry hole into the manifold measure 27mm x 42mm on the stock manifold. New stainless one is 33mm x 52 mm. Both use 42mm Outside dia tube. The collector on the stock manifold is around 2 1/4 inch O/Dia. The stainless collector is more like 2 5/8 Inch O/Dia. Bends are a tighter radius on the stainless manifold though.






I'll attempt to add a bit more to this thread tomorrow...
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Paynewright
Monza


Joined: 17 Apr 2018
Posts: 204
Location: Nr Lutterworth Leics


PostPosted: Wed Jul 04, 2018 9:17 pm    Post subject: Reply with quote

Good progress! What is the screwdriver stuck in the front pulley?

What manifolds did you go for?


Finally, are you willing ro share the cost of the engine build.


Looking forward to further installments Smile

Good luck

Ian
 
  
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Armagreggon85
Trainee


Joined: 04 Jan 2017
Posts: 93



PostPosted: Wed Jul 04, 2018 10:22 pm    Post subject: Reply with quote

Watching with interest! I've just dropped my engine off with hartech last week so awaiting a call with initial diagnosis.
 
  
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Jamesx19
Nürburgring


Joined: 10 Jul 2015
Posts: 471
Location: Brighton


PostPosted: Wed Jul 04, 2018 10:22 pm    Post subject: Reply with quote

Hi Ian,

Thanks

Screwdriver is to stop the engine spinnng when it comes time to fitting the flywheel and clutch to the crankshaft.

Manifolds are Direnza. Will pop up on ebay for around £150. Most ads don't say they are Direnza, but they are I think..

Yes, cost was £9,400. inc VAT. plus another £400 for manifolds Air Oil seperator and other parts inc a high lift jack! .... and Oil / Coolant etc.

Just under my 10K budget for a very comprehensive rebuild. I was lucky as no damage to the crankshaft, and no rubbish through the engine or damage to the oil pump. An actual failure of IMS bearing or a thrown big end would be more money. Plus of course I've saved on stripping and fitting. Figure near £12K for Hartech to do everything that mine has? Dont know


Cheers
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Last edited by Jamesx19 on Wed Jul 04, 2018 10:27 pm; edited 1 time in total
 
  
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Jamesx19
Nürburgring


Joined: 10 Jul 2015
Posts: 471
Location: Brighton


PostPosted: Wed Jul 04, 2018 10:26 pm    Post subject: Reply with quote

Good luck Armagreddon.

Grant great to deal with. makes time for you and treats questions (which he must have to answer the same ones constantly) seriously and gives a considered answer.

Hope its not too bad
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maldren
Suzuka


Joined: 07 Oct 2016
Posts: 1162



PostPosted: Thu Jul 05, 2018 11:56 am    Post subject: Reply with quote

Manifold pipes are tighter bends but they look as though they have equal pipe lengths and that should give better performance.
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Mike
2003 996.2 C2 Coupe Arctic Silver
 
  
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Jamesx19
Nürburgring


Joined: 10 Jul 2015
Posts: 471
Location: Brighton


PostPosted: Thu Jul 05, 2018 2:21 pm    Post subject: Reply with quote

I see your point Mike.

I'm unconvinced that the primary lengths are long enough to be effective at scavenging at a usable rpm any more than the stock item. Gas flow should be easier with less restrictive primary runner throats though....
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pjvenda
Silverstone


Joined: 04 Jul 2013
Posts: 141
Location: Witney

2006 Porsche 997 Carrera 2S

PostPosted: Thu Jul 05, 2018 3:04 pm    Post subject: Reply with quote

Excellent thread. Shame about the damage but great to know the engine has been rebuilt to a great spec. I wish we could have some nice photos of the engine before it had been put together (I reckon it won't happen for known reasons).

I completely agree with the reasoning of keeping the engine at 3.4L, I sometimes wish mine had less power so I could wring it more often at much more sensible speeds.

Also wanted to share my personal experience re: light weight flywheel, even though it is not slightly late in the timeline of your decision process:

- Had it fitted to my 997 carrera S just around 1y ago and it certainly does rattle. Makes for an unpleasant noise that is heard around the car especially at idle. Rattling remains audible at very low loads up to around 2.5k rpm.
*But* the downside of the experience ends there. The engine is lovely and revvy, it is significantly stronger in the 3-5k range (and I did not believe it would until I experienced it), makes for much more satisfying heel&toe downshifts, etc. Makes the car feel quite a bit more special to drive. I love it.

The conversion was done at RPM Technik and took a sprung clutch disc in place of the solid original one. Together with this work I fitted a wavetrac diff which also had a significant effect.

Cheers,
Pedro.
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