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Chief
Sepang


Joined: 16 Sep 2010
Posts: 2756
Location: The Middle lands


PostPosted: Mon Jun 10, 2013 7:47 am    Post subject: Reply with quote

Great effort. Very rewarding when things turn out looking that good Thumb

So many chaps on here doing quite extensive work, it warms the heart it really does worship
 
  
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berni29
Watkins Glen


Joined: 24 Oct 2009
Posts: 2205
Location: Kent


PostPosted: Mon Jun 10, 2013 11:21 am    Post subject: Reply with quote

Hi

Well done getting those studs out. Two of mine snapped off flush with the head and it was not fun removing those.

Berni
_________________
993 C2 Tip 1994 187k miles. Black and Grey. M029 & Bilstein HD's, Elephant Racing RS bushes F&R, RS mounts, strengthened engine carrier, 100 cell cat inserts, HID's. Solid steering arms mod, top of the engine rebuilt, mapped by Wayne, suspension set up by Chris.
 
  
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Gazc2
Watkins Glen


Joined: 08 Nov 2003
Posts: 2057
Location: Perthshire


PostPosted: Mon Jun 10, 2013 5:00 pm    Post subject: Reply with quote

Nice job and good write up Ian, all on the list for next winter if I`m not still putting the bodywork back together !
 
  
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deutschland-dobson
Indianapolis


Joined: 23 Apr 2008
Posts: 2456
Location: NE England


PostPosted: Mon Jun 10, 2013 6:12 pm    Post subject: Reply with quote

Great fan / housing colour combo, looks flippin mean Bandit

Chris
_________________
Porsche 911 (964) C4 - Project RED - Outlaw4
Guards Red & Linen, Custom Leather, BBS LM Split-rims, H&R Coilovers, Cleaned Bodywork, 90s audio instal...
 
  
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churny
Montreal


Joined: 17 Nov 2010
Posts: 501
Location: Newcastle

2003 Porsche 911

PostPosted: Mon Jun 10, 2013 6:29 pm    Post subject: Reply with quote

Great work Ian thumbsup looking forward to seeing it in the flesh
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Porsche 996 "40 jahre Anniversary" No 49
 
  
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igaffz
Albert Park


Joined: 27 Dec 2011
Posts: 1721
Location: Newcastle upon tyne


PostPosted: Mon Jun 10, 2013 8:49 pm    Post subject: Reply with quote

Cheers lads, I'm really chuffed with the way everything went, I'll defo be on the next run out Thumb
Hope everyone is keeping ok.

Ian
_________________
Horizon blue, 964 carrera 2 tip, lowered on koni's, k&n, de-cat, cup pipe, leather trim and 18" 3 piece split rims.
Silver 928 S2, B reg, manual.
Guards red 944 lux, the new project!
 
  
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KP964
Indianapolis


Joined: 20 Feb 2012
Posts: 2284
Location: Northumberland


PostPosted: Mon Jun 10, 2013 9:14 pm    Post subject: Reply with quote

Blimey , your fan and housing look very very smart Ian , great job , i just got in from 600 mile trip to Birmingham plus other places , 12 hours nearly non stop driving and gave it some stick , these cars are brilliant considering their age .
Like the photo at whittle dene sunset Thumb
_________________
Stone Grey Metallic 964 C4
Guards Red 964 C4 sold
 
  
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galair
Newbie


Joined: 20 Jul 2012
Posts: 27
Location: Heage, Derbyshire

1990 Porsche 964 Carrera 4

PostPosted: Sat Jun 15, 2013 5:29 pm    Post subject: Reply with quote

Brilliant thread mate, wish i had seen it earlier, its a bit late notice but I have a guyson blast cabinet and you or any other 964 owner would be welcome to use it, within reason of course, keep up the thread!m
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964 Guards Red
 
  
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igaffz
Albert Park


Joined: 27 Dec 2011
Posts: 1721
Location: Newcastle upon tyne


PostPosted: Mon Jun 24, 2013 6:59 pm    Post subject: Reply with quote

Well things have been a bit slow as I've been busy at work so just a few things to report.
After completing the above work I've had a few good blasts out in the car, so I jacked her back up and was a bit disappointed as there was a few places that still had oil drips Surprised
The lower chain tensioner had a drip of oil on both nuts so I decided to remove it and refit it with some instant gasket.
Upon removing it it became apparent I would not be able to use the instant gasket as there's an oil feed hole in the gasket, this must push oil through the hole and lubricate the tensioner spring, I was afraid if i used the sealer it might push out the sides and clog the hole Dont know

Pic of gasket

Pic of tensioner

I've cleaned everything and refitted it, I'll have to order a new gasket from porsche!
I noticed a few oil runs at the nuts that fix the heads to the engine. I managed to get a 10mm spanner onto the oily one and get a good couple of turns on the nuts, they weren't tight!

Ok lads, the next major thing I'm going to attempt is the crank shaft oil seal(pulley end) as I have some oil deposits below this area.
Anyone attempted this? I've done a few searches and it seems straight forward apart from having to reassemble using a dial gauge?
I'll attempt the crank shaft oil seal and the chain tensioner gasket over the next couple of weeks and let you guys know how it goes.

Ps the left hand side of the engine is totally dry thumbsup
The right hand side has oil under the tensioner as above and the right hand side lower cam cover has oil drips in numerous places, I think I will try removing it and use the sealer and stick it back down and see if this works?



Ian
_________________
Horizon blue, 964 carrera 2 tip, lowered on koni's, k&n, de-cat, cup pipe, leather trim and 18" 3 piece split rims.
Silver 928 S2, B reg, manual.
Guards red 944 lux, the new project!
 
  
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KP964
Indianapolis


Joined: 20 Feb 2012
Posts: 2284
Location: Northumberland


PostPosted: Mon Jun 24, 2013 9:32 pm    Post subject: Reply with quote

Perseverance there Ian , hope someone can provide a little more info about the crank shaft oil seal , although im sure between you , your pop , and the net you will sort it anyway. Thumb
_________________
Stone Grey Metallic 964 C4
Guards Red 964 C4 sold
 
  
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PeterS
Fuji


Joined: 01 Nov 2009
Posts: 9293
Location: Solihull

2003 Porsche 996 Carrera 2

PostPosted: Tue Jun 25, 2013 5:41 pm    Post subject: Reply with quote

This is really good stuff, keep it up.

Interesting to see the black fan, not to everybody's taste.
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igaffz
Albert Park


Joined: 27 Dec 2011
Posts: 1721
Location: Newcastle upon tyne


PostPosted: Mon Jul 08, 2013 9:18 pm    Post subject: Reply with quote

Hi lads, been using the car and watching for leaks since the previous work. Well the left side of the engine(cam comers) and the engine block are totally dry. Unfortunately the right hand cam covers top and bottom are both leaking my new oil! Also the very bottom nut on both chain covers are wet with oil?
Today I've removed the cup pipe and back box plus tin wear and heat shielding from the right side and rear of the engine. I've dropped the oil from the car also. I'm working tomorrow but hope to remove the cam covers and chain covers on Wednesday or Thursday. I've got some gasket sealer that I'm going to try and use some of this on the wet areas and re torque the covers back down.
I've also got some fresh oil evident on the nuts that hold the engine carrier to the engine under the pulleys, I think this is comming from the crank shaft oil seal but not 100% I'll know when I remove the engine carrier and the pulleys later in the week.
Pic of oil under the crank area?



Any one else had oil leaking from this area?
I've got a new crank shaft oil seal and lower chain tensioner cover gasket as this is a bit wet also. I shall hopefully have good news to report later in the week.


Ian
_________________
Horizon blue, 964 carrera 2 tip, lowered on koni's, k&n, de-cat, cup pipe, leather trim and 18" 3 piece split rims.
Silver 928 S2, B reg, manual.
Guards red 944 lux, the new project!
 
  
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igaffz
Albert Park


Joined: 27 Dec 2011
Posts: 1721
Location: Newcastle upon tyne


PostPosted: Tue Jul 09, 2013 10:32 pm    Post subject: Reply with quote

Managed to get some work done on the car today, removed the cam covers from the right hand side of the engine, cleaned the covers and gaskets then used some gasket seal along the bottoms of the covers. Also removed the chain covers and used the same sealer along the bottoms of each cover then tightend them back down to the correct torques.
Also managed to remove the right lower side chain tensioner cover and fit a new gasket.(I should have done that the first time round).
That just leaves the crank shaft oil seal, I've saved the best till last! I'll document this soon, going on my jollys on Monday so hoping to be finished befor then.



Ian
_________________
Horizon blue, 964 carrera 2 tip, lowered on koni's, k&n, de-cat, cup pipe, leather trim and 18" 3 piece split rims.
Silver 928 S2, B reg, manual.
Guards red 944 lux, the new project!
 
  
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igaffz
Albert Park


Joined: 27 Dec 2011
Posts: 1721
Location: Newcastle upon tyne


PostPosted: Thu Jul 11, 2013 10:53 pm    Post subject: Reply with quote

Well made some progress today, removed the belts and engine carrier from the rear of the car. I intended to remove the pulley wheel so I could gain access to the crank shaft oil seal. Surprisingly the oil seemed to be coming from the intermediate shaft cover located directly under the crank shaft.
Pic of intermediate shaft

And pic of cover with hard old perished seal

I've ordered a new seal from Newcastle OPC, ready for collection on Saturday
I knew there was a nut missing from the engine carrier that the heat exchanger pipe bolts to so I got my bro to weld a new nut on for me

I've primed and sprayed it black ready for refitting.
I wish I hadn't removed the belts now as they could have stayed on now that I'm not doing the crank shaft oil seal!
I can't do anything now tomorrow till I get the new seal on Saturday.
Thought I better cut some wood to help the jack out as it has a habit of going down over night Surprised don't want to get up in the morning and find my engine on the floor!

Ian
_________________
Horizon blue, 964 carrera 2 tip, lowered on koni's, k&n, de-cat, cup pipe, leather trim and 18" 3 piece split rims.
Silver 928 S2, B reg, manual.
Guards red 944 lux, the new project!
 
  
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Tokyo Joe
Montreal


Joined: 04 Sep 2009
Posts: 538
Location: Tokyo

1996 Porsche 993 Turbo

PostPosted: Fri Jul 12, 2013 11:57 pm    Post subject: Reply with quote

Inspiring Thumb

You've got talent that's for sure. Thanks for cataloging.
_________________
964 C2 1990
993 Turbo 1996 (X50)
Previous;
993 Carrera 1995
986 Boxster 2001
 
  
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PeterS
Fuji


Joined: 01 Nov 2009
Posts: 9293
Location: Solihull

2003 Porsche 996 Carrera 2

PostPosted: Sat Jul 13, 2013 8:42 am    Post subject: Reply with quote

Great to see these threads. I hope it's back together today, time for a blast before your holiday.
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berni29
Watkins Glen


Joined: 24 Oct 2009
Posts: 2205
Location: Kent


PostPosted: Sat Jul 13, 2013 8:52 am    Post subject: Reply with quote

Hi

Nice work.

When you did the timing chain covers did you use new grommets or were the old ones still nice and soft? Also what sealer did you use? I am getting to be of the opinion that the sealants in places like that do more harm than good.

Berni
_________________
993 C2 Tip 1994 187k miles. Black and Grey. M029 & Bilstein HD's, Elephant Racing RS bushes F&R, RS mounts, strengthened engine carrier, 100 cell cat inserts, HID's. Solid steering arms mod, top of the engine rebuilt, mapped by Wayne, suspension set up by Chris.
 
  
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igaffz
Albert Park


Joined: 27 Dec 2011
Posts: 1721
Location: Newcastle upon tyne


PostPosted: Sat Jul 13, 2013 7:32 pm    Post subject: Reply with quote

Yes I used new timing chain gaskets and all new grommets from Porsche, I used a little of the sealant on the bottom edge only as I couldn't get the lowest part of the covers to stay dry. I also used it on the bottom edge of the upper right hand cam cover and around the whole lower cam cover.

I had taken pics of the new rubber seal picked up from OPC this morning along side the old one but my phone must be full cos there nowhere to be found Dont know it was interesting to see how much different the new seals compared to the old, if they go so brittle and thin it's no wonder they leak oil!!!
Anyway I've gotten the shaft seal done and the oil back in and everything put back together, I've only got the belts to tension in the morning and its finished! Next job is to clean under the arches Smile
_________________
Horizon blue, 964 carrera 2 tip, lowered on koni's, k&n, de-cat, cup pipe, leather trim and 18" 3 piece split rims.
Silver 928 S2, B reg, manual.
Guards red 944 lux, the new project!
 
  
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igaffz
Albert Park


Joined: 27 Dec 2011
Posts: 1721
Location: Newcastle upon tyne


PostPosted: Thu Jul 25, 2013 8:11 pm    Post subject: Reply with quote

Well didn't manage to get the belts on befor I went on holiday as I'd left the boot lid open and the battery went flat Embarassed anyway back now and it's charging so belts should be on tomorrow and I'll be back on the road!
Managed to find the missing pic of the intermediate shaft cover seal, you can see how the orange (old) seal is shrunk and out of shape compared to the new green seal, no wonder they leak!


Ian
_________________
Horizon blue, 964 carrera 2 tip, lowered on koni's, k&n, de-cat, cup pipe, leather trim and 18" 3 piece split rims.
Silver 928 S2, B reg, manual.
Guards red 944 lux, the new project!
 
  
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igaffz
Albert Park


Joined: 27 Dec 2011
Posts: 1721
Location: Newcastle upon tyne


PostPosted: Tue Aug 27, 2013 9:16 pm    Post subject: Reply with quote

When I had the car stripped down I wasn't happy with the gap in the engine mounts so I picked a good second hand pair up on ebay.

I didn't know at the time but when they came it turned out they where from Douglas valley, and for £30 with free delivery I thought that was a bargain!
I nearly had a baby when I say how much they are new Surprised
Anyway got the first 3 bolts out and Sod's law kicked in and you've guessed it the 4 bolt snapped! Sad
Pic shows the poor condition of the bolts, apart from one that looks almost new?

Anyway thought I had better try and drill the snapped bolt out. Masked up the car to avoid damage to the panel if I slipped!

This turned out to be a bit of a pain, I had to get some long drill bits to reach the bolt, but with a bit of drilling and hammering I got the blighter out.
Next I turned a tap through the hole to cut some new threads into the captive nut.

Down to my local nut and bolt supplier and got the exact same bolts for £2!

Anyway the original mounts turned out to be in better nick than I thought, the left one looks fine but the gap in the right one is definitely a bigger that the other.

All fitted tonight, just a couple of electrical gremlins to track down!



Ian
_________________
Horizon blue, 964 carrera 2 tip, lowered on koni's, k&n, de-cat, cup pipe, leather trim and 18" 3 piece split rims.
Silver 928 S2, B reg, manual.
Guards red 944 lux, the new project!
 
  
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