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jond58
Spa-Francorchamps


Joined: 19 Jun 2017
Posts: 260
Location: York


PostPosted: Tue Dec 31, 2019 9:40 pm    Post subject: Reply with quote

Bit of an update!!! 9.30pm New Year’s Eve?!? This is going to cross decades!!!!
Anyway, all off, all drilled and basically five studs in one slide and three in the other. I’ve four to deal with, these seem a nightmare but that maybe just because it’s cold and a long day. I only have a second tap rather than a first and a second so I’ve been picking out the first few threads and then going at it but these are having none of it!! I think I have a first tap at home in the garage so back here tomorrow to hopefully get more done.
Brackets are on, thermostats back on and plenty of other bits so it’s been a good day.
Two came out on that side today with welded nuts on so that was some good news
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jond58
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PostPosted: Tue Dec 31, 2019 9:47 pm    Post subject: Reply with quote

Oh, and happy new year to everyone!!!
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Scholester
Suzuka


Joined: 16 Jan 2012
Posts: 1133
Location: South West


PostPosted: Wed Jan 01, 2020 10:17 am    Post subject: Reply with quote

jond58 wrote:
Steel studs with aluminium paste, copper/brass flange nuts on stainless spring washers. This is what I’ve done loads of times with motorbikes never had any issues with this set up. Marine grade stainless for literally every other fixing.

Thumb
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Scholester
Suzuka


Joined: 16 Jan 2012
Posts: 1133
Location: South West


PostPosted: Wed Jan 01, 2020 10:25 am    Post subject: Reply with quote

jond58 wrote:
Bit of an update!!! 9.30pm New Year’s Eve?!? This is going to cross decades!!!!
Anyway, all off, all drilled and basically five studs in one slide and three in the other. I’ve four to deal with, these seem a nightmare but that maybe just because it’s cold and a long day. I only have a second tap rather than a first and a second so I’ve been picking out the first few threads and then going at it but these are having none of it!! I think I have a first tap at home in the garage so back here tomorrow to hopefully get more done.
Brackets are on, thermostats back on and plenty of other bits so it’s been a good day.
Two came out on that side today with welded nuts on so that was some good news

Great work.
You will enjoy 2020 knowing that the job has been done right thumbsup
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jond58
Spa-Francorchamps


Joined: 19 Jun 2017
Posts: 260
Location: York


PostPosted: Wed Jan 01, 2020 11:57 am    Post subject: Reply with quote

Bit of a sleepless night mulling things over in my mind so down here early to check something that bothered me and sure enough some thinking time was all that was required.
Couldn’t quite figure out why the last four holes seemed such an impossibility to shell the thread from. Vernier calipers out and that drill bit has done too much!! 17/64 is approx 6.75mm. That drill bit is 6.607 so looks like I’m not quite done with drilling. Very slow and careful cleaning pass required but obviously it’s New Year’s Day so that ain’t happening today as no where is open!! Had literally every drill bit I own out to see if i had anything. I don’t!!
Going to have a tidy up and list some bits for sale that I’ve removed. Jig will be for sale once I’ve actually finished with it!!!!
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nickyg63
Trainee


Joined: 25 Aug 2019
Posts: 55



PostPosted: Wed Jan 01, 2020 6:50 pm    Post subject: Reply with quote

Awesome work, one of those jobs thats you are in for a penny!! Would be nice to hear if that car feels any better with all of the nice new shiny bits??

All the best and a happy new year to you

Cheers Nick
 
  
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jond58
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Joined: 19 Jun 2017
Posts: 260
Location: York


PostPosted: Wed Jan 01, 2020 7:22 pm    Post subject: Reply with quote

Yeah, once you’re committed you’re definitely committed! I’m just feeling silly about not getting a load of 17/64 drill bits. I bought a load of the smaller ones but I guess in my mind I didn’t think I’d be drilling this many bolts out! I’m not in a rush it’s just I have to keep reminding myself of that fact!
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berni29
Watkins Glen


Joined: 24 Oct 2009
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PostPosted: Wed Jan 01, 2020 9:35 pm    Post subject: Reply with quote

Hi

I have done this horrible job on my 993 and when refitting the manifold nuts used 12mm copper coated ones as used by Lotus Esprit Turbo owners. I was told SS ones will anneal to the steel studs.

Well done!

Bernard
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Hughb
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Joined: 15 Jul 2019
Posts: 61
Location: Somerset


PostPosted: Thu Jan 02, 2020 12:26 am    Post subject: Reply with quote

Massive ‘well done’ so far ...... but agree with Jezgreen .... those of us who have this job in front of us were desperately hoping for a greater success rate with actual stud wind outs, especially with the array of kit lined up against them. I would now be approaching this job with a far lower expectation of successful wind-outs from something like 50:50 that I would have had before your post.
Can you summarise what was helpful and what was not worth the effort in terms of ‘persuasion’ on the studs. I get the impression that Penetrating oil, heat cycling, laser stud extraction contributed little. Do you retrospectively think that heat cycling may have contributed brittleness, causing so many to snap off. I have read another documented stud removal case where no heat was used, but each bolt head was trimmed back to stud 8mm dia to enable flange removal (had to cut up the manifold in situ to get access to nuts) and then laser stud extraction tool was used fairly successfully.
How did you get on with the exhaust hanger bolts (into engine block)?
Great posts. .... thanks
 
  
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jond58
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Joined: 19 Jun 2017
Posts: 260
Location: York


PostPosted: Thu Jan 02, 2020 8:51 am    Post subject: Reply with quote

I think that every engine will be different. How many heat cycles it’s done, how close it’s been to the seaside, has it been garaged etc etc. At some point I assume this may have been used to tow life boats on and off a slipway because these were heavily corroded!!!

Anyway, retrospectively the only thing different I would have done was to try welding more nuts on the first side. We got two or three out of the other side with that technique and Bruce had bought some new welding tips so I think if we had our time again we’d probably focus on that for a little longer. That said I think the best we would have achieved would be 50% removal so there’s always going to be drilling.

Penetrating oil does nothing!! As I suspected. I had loads on for days on end the studs were as dry as a bone so it’s only psychological assistance that’s giving!

I guess it depends how much stud is left showing, a bit more and that stud extractor may have been useful but it’s a frustrating tool to get on with it slipping off.

The exhaust supports have frustrated me! Bolts removed with two cycles of the induction tool and replaced with stainless. There are two upper bolts each side. I thought Porsche would have left access behind a heat shield that sits on the inner wing.....they didn’t so that’s an engine out job. The only good news there is that owning one of these means you just need to wait till that job comes round!!!!!
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jond58
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Joined: 19 Jun 2017
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Location: York


PostPosted: Thu Jan 02, 2020 3:15 pm    Post subject: Reply with quote

I prayed hard for a win today!!!
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Alex
Le Mans
Le Mans


Joined: 06 Mar 2014
Posts: 17199
Location: The Ribble Valley, Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Thu Jan 02, 2020 5:13 pm    Post subject: Reply with quote

jond58 wrote:

The exhaust supports have frustrated me! Bolts removed with two cycles of the induction tool and replaced with stainless. There are two upper bolts each side. I thought Porsche would have left access behind a heat shield that sits on the inner wing.....they didn’t so that’s an engine out job. The only good news there is that owning one of these means you just need to wait till that job comes round!!!!!


Are you on about these (see photo)?

You remove them from the brackets (with the three bolts you can see) then dismantle them from the back boxes off line. Then assemble them to the new back boxes and then bolt back on the brackets.



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jond58
Spa-Francorchamps


Joined: 19 Jun 2017
Posts: 260
Location: York


PostPosted: Thu Jan 02, 2020 7:18 pm    Post subject: Reply with quote

No not them!!! I replaced them with new ones but I have the metal tubular bits to replace those but the top bolts on those are in the engine bay..........somewhere!!!
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Alex
Le Mans
Le Mans


Joined: 06 Mar 2014
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2000 Porsche 996 Carrera 4

PostPosted: Thu Jan 02, 2020 7:31 pm    Post subject: Reply with quote

You've lost me. Didn't think any exhaust part needed an engine drop. Dont know

Edit: Yeah - I know where you mean now Duh
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jond58
Spa-Francorchamps


Joined: 19 Jun 2017
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Location: York


PostPosted: Thu Jan 02, 2020 10:07 pm    Post subject: Reply with quote

These matey!!!!
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jond58
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PostPosted: Thu Jan 02, 2020 10:08 pm    Post subject: Reply with quote

Coolant filled back up, all done!! Too late to fire it though sadly!
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jond58
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PostPosted: Thu Jan 02, 2020 10:09 pm    Post subject: Reply with quote

Can’t wait!
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jezgreen911
Nürburgring


Joined: 12 Dec 2012
Posts: 442
Location: Bucks


PostPosted: Fri Jan 03, 2020 5:20 am    Post subject: Reply with quote

Great to see the car all back together and what has to be one of the worst 996 jobs all done Thumb

What cats are you running now?
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jond58
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Joined: 19 Jun 2017
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Location: York


PostPosted: Fri Jan 03, 2020 8:23 am    Post subject: Reply with quote

The set up is, Toyosport manifolds, topgear 200cell cats, milltek boxes. Considering that’s from three separate manufacturers with some Porsche parts it all went together fine. I was a bit nervous of that but no issues at all. It’s the little things that matter such as doing the job yourself let’s you line up brackets where you want them. I’ve tried to make sure nothing is in the way of road debris and weather, same with hose clips I’ve replaced.
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Shalmaneser
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Joined: 11 Nov 2019
Posts: 44



PostPosted: Fri Jan 03, 2020 9:22 am    Post subject: Reply with quote

This is gonna sound great! Quite a job, well done to the both of you.
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