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BillCoupe98
Newbie


Joined: 11 Dec 2016
Posts: 28
Location: South West


PostPosted: Wed Apr 17, 2019 6:20 pm    Post subject: Replacing exhaust Reply with quote

After 3 years of trouble free daily driving and 18000 miles the flexis on my Dansk silencers have split Mad

So i have decided to refurbish the exhaust system using man maths and parts collected over the last 3 years

The silencers are now with topgear in bridport for new flexis, and i have a 63mm x pipe on order, coupled with my cheap ebay manifolds will give me a full 2.5" system as thr manifolds and silencers are 2.5" tubes already

One full day stripping the exhaust system, 8 snapped bolts later, i'm now using the stromski jig to remove the left over studs Smile
 
  
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BillCoupe98
Newbie


Joined: 11 Dec 2016
Posts: 28
Location: South West


PostPosted: Wed Apr 17, 2019 6:21 pm    Post subject: Reply with quote

Car set up on midrise lift in garage
 



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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7203
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Wed Apr 17, 2019 6:31 pm    Post subject: Reply with quote

Good luck with the jig. Are you replacing with studs?

MC
 
  
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BillCoupe98
Newbie


Joined: 11 Dec 2016
Posts: 28
Location: South West


PostPosted: Wed Apr 17, 2019 6:37 pm    Post subject: Reply with quote

Hi

Yes, i,ve drilled 2 out so far, jig is easy to use, i haven't deciede yet on replacements can either go old fashioned and use normal vw type steel studs with copper nuts or use SS bolts

Good job i took 2 weeks holiday Thumb
 
  
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Alex
Le Mans
Le Mans


Joined: 06 Mar 2014
Posts: 16667
Location: The Ribble Valley, Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Wed Apr 17, 2019 6:54 pm    Post subject: Reply with quote

My SS bolts were removed last month after being in for 4 years. Clean as a whistle and trouble free.
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2000 Manual 996 C4 Arctic Silver Convertible


 
  
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Paynewright
Monza


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


PostPosted: Wed Apr 17, 2019 9:31 pm    Post subject: Reply with quote

Watching with interest as still on the to-do list. Stomski and TI studs already purchased.

So info on your experience would be useful eg did the threads ‘peel’ out or did they need tapping? Any specific tools that you used in addition to the stomski? Did all 6 snap one side - how easy was it to locate the jig on stud remnants ?

Regards

Ian
 
  
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jezgreen911
Nürburgring


Joined: 12 Dec 2012
Posts: 419
Location: Bucks


PostPosted: Thu Apr 18, 2019 6:18 am    Post subject: Reply with quote

Paynewright wrote:
Watching with interest as still on the to-do list. Stomski and TI studs already purchased.

So info on your experience would be useful eg did the threads ‘peel’ out or did they need tapping? Any specific tools that you used in addition to the stomski? Did all 6 snap one side - how easy was it to locate the jig on stud remnants ?

Regards

Ian


+1 Thumb
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Alex
Le Mans
Le Mans


Joined: 06 Mar 2014
Posts: 16667
Location: The Ribble Valley, Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Thu Apr 18, 2019 6:39 am    Post subject: Reply with quote

Don't know why anyone would want to fit Titanium in Aluminium. They are at either ends of the Galvanic scale so are prone to react with each other as there's chance the Titanium will act as an Anode and eat away at the Aluminium.

I have Titanium implants in the front of my face. The reason Titanium is used is due to its excellent ability to knit into other materials and form a permanent bond so it doesn't come loose. Why the hell would you want this to happen with your manifold bolts - I thought the idea was to fit something that can easily be removed at a later date Dont know

If you want to play it safe, just fit Stainless Steel Bolts. There cheaper and will be far better suited to the job.
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BillCoupe98
Newbie


Joined: 11 Dec 2016
Posts: 28
Location: South West


PostPosted: Thu Apr 18, 2019 7:08 am    Post subject: Reply with quote

7 bolts snapped, 1 head was so bad i couldnt use a socket so had to drill it off freehand, so all 6 one side need removing.

I used a 3" air powered cut off tool to cut some of the stud.

I have removed the thermostat and the waterpump hose and removed the 10mm bolts holding the waterpipes ether side of the sump for access.

A normal drill wont fit on the front stud, passenger side, as the chuck rubs on the engine casing, it was mentioned in the stromski u tube video so i was ready for it, i have access to a handheld chuck on an extension powered by my battery drill so It wasnt an issue.

The studs in mine the 2 ive done so far havn't peeled out, i used the chasing tap in the kit to clean them out, you have to be patient.

Its not a job i would like to attempt without a lift simply because you need lots of light, although that could be my eyesight
Cool
 
  
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Paynewright
Monza


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


PostPosted: Thu Apr 18, 2019 7:18 am    Post subject: Reply with quote

So what would be the electrolyte?
 
  
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Alex
Le Mans
Le Mans


Joined: 06 Mar 2014
Posts: 16667
Location: The Ribble Valley, Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Thu Apr 18, 2019 7:27 am    Post subject: Reply with quote

Whatever made the steel ones fuse in there in the first place. Just my opinion but why buy some whizzy component (lets be honest - we all get a hard on when Titanium is mentioned) when a 20 pack of £2.50 Stainless Steel bolts are perfectly adequate. Cheaper than a pack of fags and do less damage.
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BillCoupe98
Newbie


Joined: 11 Dec 2016
Posts: 28
Location: South West


PostPosted: Thu Apr 18, 2019 7:34 am    Post subject: Reply with quote

Passenger side manifold bolts
 



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BillCoupe98
Newbie


Joined: 11 Dec 2016
Posts: 28
Location: South West


PostPosted: Thu Apr 18, 2019 7:38 am    Post subject: Reply with quote

Underneath of head
 



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Paynewright
Monza


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


PostPosted: Thu Apr 18, 2019 8:18 am    Post subject: Reply with quote

That looks challenging! Keep us updated.

Mine on drivers side look similarly corroded. Plan is to do Nov / Dec time so I can do steadily.

Alex - good insight on metals to use. I’m still erring towards studs and nuts but in stainless now!

Ian
 
  
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Alex
Le Mans
Le Mans


Joined: 06 Mar 2014
Posts: 16667
Location: The Ribble Valley, Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Thu Apr 18, 2019 8:20 am    Post subject: Reply with quote

See that groove machined in the head that goes to each cylinder? Evertime you start the engine cold, the SAI unit (if you have one) sucks whatever is in the surrounding atmosphere and pumps it through those channels and round the bolts.
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cvega
Spa-Francorchamps


Joined: 25 Feb 2013
Posts: 252
Location: Cambridge


PostPosted: Thu Apr 18, 2019 8:56 am    Post subject: Reply with quote

Good luck, I'll certainly be paying someone else to do this... Sad
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2003 996 C2
2017 Leaf 30kWh
gone: 2010 335d, 2007 Cayman S, 2008 Civic Type-R, 1992 MR2 Turbo ,1994 MR2 N/A
 
  
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Bluebird911
Nürburgring


Joined: 29 May 2010
Posts: 453



PostPosted: Thu Apr 18, 2019 9:51 am    Post subject: Reply with quote

Paynewright wrote:
So what would be the electrolyte?


You are quite right, that without an electrolyte, there is no galvanic corrosion, but as Alex points out, it is bad engineering practice to use a combination of metals with the potential for this type of reaction. If the car is not routinely used, moisture could condense in / near the threaded areas. Heat is also needed for a galvanic reaction, but in this case it is your friend as the high temps would evaporate any potential electrolyte. I can't see how Ti has any benefit over SS in this application. I recall this matter was discussed at reasonable length about 9 months ago.
 
  
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BillCoupe98
Newbie


Joined: 11 Dec 2016
Posts: 28
Location: South West


PostPosted: Thu Apr 18, 2019 11:16 am    Post subject: Reply with quote

Slow progress, another tight spot where normal drill won’t get in
 



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BillCoupe98
Newbie


Joined: 11 Dec 2016
Posts: 28
Location: South West


PostPosted: Fri Apr 19, 2019 12:52 pm    Post subject: Reply with quote

Passenger side complete, 8 studs drilled and chased out with the tap supplied in the kit

Very happy, just the 2 to do in the drivers side and it will be finished
Very Happy
 



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BillCoupe98
Newbie


Joined: 11 Dec 2016
Posts: 28
Location: South West


PostPosted: Fri Apr 19, 2019 3:21 pm    Post subject: Reply with quote

Drivers side, what’s left of the studs cleaned up with an 8mm die, gold thumbscrew needs a large washer added as it doesnt fit fit flush with the head and won’t keep the jig tight to the head if it’s not fitted
 
  
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