IPB-Autosport 996 GT3 4 Liter [Archive] - PCA GT2, GT3 and Cup Car SIG

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IPB-Autosport

05-10-2011, 02:10 AM

While many are scrambling to find an RS 4.0 allocation, we are taking a different approach. Allow me to introduce the IPB-Autosport 4 liter project.

http://www.ipb-autosport.com/nav/2-header.jpg
https://lh5.googleusercontent.com/_PCzAS4nZTAE/TcjixbwHl7I/AAAAAAAAAbA/u97HWK7rA-E/s800/4%20liter%20logo.jpg

First things first, the engine has to come out. After removing the airbox, draining and disconnecting the coolant system, evacuating the A/C, disconnecting power steering lines, fuel lines, engine harness, misc vacuum lines, etc, the car goes up in the air.

https://lh3.googleusercontent.com/_PCzAS4nZTAE/TcjbLwVHpKI/AAAAAAAAAXs/e3WUXXl83t8/s800/2.jpg

Once the plastic underbody panels are removed, we gain access to everything else that has to be disconnected: axles, cross members, sway bar, starter, ground, transmission cables, clutch slave, additional coolant lines including the tranny cooler, and of course engine/transmission mounts. The whole unit drops out.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TcjbMO2JTNI/AAAAAAAAAXw/Pi_TnyP9NOU/s800/3.jpg

It’s massive.

https://lh4.googleusercontent.com/_PCzAS4nZTAE/TcjbMeKy0gI/AAAAAAAAAX0/CcYImGqGv8E/s800/4.jpg

The engine and transmission is split and the clutch is removed. Stock flywheel isn’t light. An RS LWFW will be taking its place.

https://lh4.googleusercontent.com/_PCzAS4nZTAE/TcjbNJqL3rI/AAAAAAAAAYA/G5yTNuVsgac/s800/7.jpg

Clutch plate still looks good.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TcjbNljHLnI/AAAAAAAAAYE/QUSF2pugysw/s800/8.jpg

Two studs are pulled and the engine is secured with allens.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TcjbMrmHxKI/AAAAAAAAAX4/rThq1VggGDA/s800/5.jpg
https://lh5.googleusercontent.com/_PCzAS4nZTAE/TcjbM8YVCQI/AAAAAAAAAX8/TBif9SsM9wc/s800/6.jpg

Out comes the oil tank and associated lines.

https://lh4.googleusercontent.com/_PCzAS4nZTAE/TcjbN4YwYpI/AAAAAAAAAYM/rJ-9qiT9QzQ/s800/9.jpg
https://lh4.googleusercontent.com/_PCzAS4nZTAE/TcjbOC8DysI/AAAAAAAAAYQ/A6s0zXKpnt4/s800/10.jpg

Next the intake manifold.

https://lh5.googleusercontent.com/_PCzAS4nZTAE/TcjbOspCoKI/AAAAAAAAAYU/jV0Nxal8VIc/s800/11.jpg
https://lh5.googleusercontent.com/_PCzAS4nZTAE/TcjbO529p7I/AAAAAAAAAYY/bxWg5SsGyu0/s800/12.jpg
https://lh3.googleusercontent.com/_PCzAS4nZTAE/TcjbPPnudWI/AAAAAAAAAYc/3WRJYd8knlQ/s800/13.jpg
https://lh3.googleusercontent.com/_PCzAS4nZTAE/TcjbPQot3LI/AAAAAAAAAYg/AvhjLWK2LGM/s800/14.jpg

Oil cooler and cooling manifold come out.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TcjbPpyXLFI/AAAAAAAAAYk/ia_4cAgWpZI/s800/15.jpg
https://lh4.googleusercontent.com/_PCzAS4nZTAE/TcjbPxuQLDI/AAAAAAAAAYo/N84fg2b-9R0/s800/16.jpg

Alternator and A/C compressor comes next.

https://lh5.googleusercontent.com/_PCzAS4nZTAE/TcjbQAGImtI/AAAAAAAAAYs/u51KdyxeIYQ/s800/17.jpg

Power steering pump and reservoir.

https://lh5.googleusercontent.com/_PCzAS4nZTAE/TcjbQ4dZCZI/AAAAAAAAAY0/RqprTxjDBFQ/s800/18.jpg

Water pump comes out last.

https://lh4.googleusercontent.com/_PCzAS4nZTAE/TcjbRKXfMhI/AAAAAAAAAY4/ockcR-EeOyE/s800/19.jpg

We are down to a long block.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TcjbQRDogGI/AAAAAAAAAYw/GAJxawzEy7Q/s800/20.jpg

All the parts are stashed on a cart, and the transmission sits nearby. Once the case is split and sent off to machining, the differential will be pulled and rebuilt with Guard internals.

https://lh4.googleusercontent.com/_PCzAS4nZTAE/TcjbTgGdA2I/AAAAAAAAAZY/cmC7SHUagsI/s800/21.jpg

In the engine room is a freshly rebuild air cooled engine waiting to go into a genuine 914-6. Numerous flat-6 engine parts everywhere – accumulated through years of engine building experience.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TcjbRXI8UyI/AAAAAAAAAY8/EA8xX_N_ryw/s800/22.jpg

My engine is next to a 993 GT2 Evo 3.8. Cool, huh?

https://lh3.googleusercontent.com/_PCzAS4nZTAE/TcjbRpukPgI/AAAAAAAAAZA/aCwuFLVC_j0/s800/23.jpg

We need more motivation in this room. Ah yes, the Wurth calendar!

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TcjbSALlesI/AAAAAAAAAZE/y-g3tkjHudU/s800/24.jpg

Cam covers come off with the motivation of big orange.

https://lh5.googleusercontent.com/_PCzAS4nZTAE/TcjbScx_nMI/AAAAAAAAAZI/2_6gqWIHLCI/s800/25.jpg
https://lh5.googleusercontent.com/_PCzAS4nZTAE/TcjbSi4mu-I/AAAAAAAAAZM/_d8SC6i36G8/s800/26.jpg

Out come the chain tensioners.

https://lh4.googleusercontent.com/_PCzAS4nZTAE/TcjbTOdzdsI/AAAAAAAAAZQ/_i5HV6_6y1A/s800/27.jpg

Porsche specialty tools are used to hold the cam gears in order to loosen the nuts.

https://lh3.googleusercontent.com/_PCzAS4nZTAE/TcjbTU4lUvI/AAAAAAAAAZU/1qORIMCJ9OU/s800/28.jpg

Lifters are now exposed. These are placed into a labeled bin so that they can be reused in the same locations.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TcjbT-1qoFI/AAAAAAAAAZc/GE6EbVerIYk/s800/29.jpg

Timing chain housings and cam housings come out.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TcjbUOjVqeI/AAAAAAAAAZg/sgHbTft2_kc/s800/30.jpg

Then the heads.

https://lh3.googleusercontent.com/_PCzAS4nZTAE/TcjbUUJdldI/AAAAAAAAAZk/hzKFlZlxd_4/s800/31.jpg

Parts lay on the work table.

https://lh3.googleusercontent.com/_PCzAS4nZTAE/TcjbUqOMYjI/AAAAAAAAAZo/lN2-bHy3vco/s800/32.jpg
https://lh6.googleusercontent.com/_PCzAS4nZTAE/TcjbU8cKFXI/AAAAAAAAAZs/55IH2zkuLJI/s800/33.jpg

Cylinders slide off exposing the pistons.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TcjbVNhJtJI/AAAAAAAAAZw/F7Gz7ZqJUag/s800/34.jpg
https://lh5.googleusercontent.com/_PCzAS4nZTAE/TcjbVUejtsI/AAAAAAAAAZ0/hg-OH6Tx3CM/s800/35.jpg

Pistons are unclipped.

https://lh5.googleusercontent.com/_PCzAS4nZTAE/TcjbVzNRJ5I/AAAAAAAAAZ8/IaUNtbRwnkU/s800/36.jpg
https://lh4.googleusercontent.com/_PCzAS4nZTAE/TcjbWC2j22I/AAAAAAAAAaA/my46-NIliiI/s800/37.jpg

Time to split the case.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TcjbWavY6pI/AAAAAAAAAaE/UL8HHDhibtQ/s800/38.jpg

The engine stand is struck with a hammer to shock the case.

https://lh3.googleusercontent.com/_PCzAS4nZTAE/TcjbW0KHP7I/AAAAAAAAAaI/iKxGcfb4Noc/s800/39.jpg
https://lh3.googleusercontent.com/_PCzAS4nZTAE/TcjbXN7CF8I/AAAAAAAAAaQ/BNnD6aCg4fA/s800/40.jpg

The internals are beautiful.

https://lh3.googleusercontent.com/_PCzAS4nZTAE/TcjbXVpVeOI/AAAAAAAAAaU/QW4Kmhh5QRg/s800/41.jpg

That's all for tonight - the past few days have been exhausting!

FTS

05-10-2011, 02:36 AM

I have to say, love the post, pics and story development, thank you. This is pure car porn, like undressing your significant other on a pole :D

Thank you for the detail pictures, fantastic to see all these details.

Also, just as a note to everyone, these types of posts are very educational for most of us, and as long as vendors (who are enthusiasts like us) keep sharing technical information with the community and avoid engaging in direct sales activities, such as listing prices for products or services, or just trying free advertising, I welcome their participation in our community. It is a fine line, and we will do our best to walk on it carefully. If you have a differing view on this matter, please do email/pm me privately, at the end this is your community, we are only here to administer it for our members.

Cheers,

landjet

05-10-2011, 05:33 AM

Ron, nice project. How many HP will the 4.0 yield?

Do you have any pictures of the coolant manifolds after repair using your method of welding in the stock fittings?

TRAKCAR

05-10-2011, 12:31 PM

Me Likey!

Can't wait to see the progress, dyno results and laptimes. Ideally with before and after overlays. That's all.

Trackrat

05-10-2011, 12:33 PM

Following with curiosity as well.

cfjan

05-10-2011, 12:56 PM

The one done by Musante/EPL ended up making 450hps or so? Here's the link to the EPL website:

http://www.eplabs.net/products/porsche/gt3/musante-motorsports-gt3-4-0l-conversion-kit/

IPB-Autosport

05-10-2011, 01:11 PM

I will be posting pics of each step along the way, as well as pics of all enhancements to improve reliability.

landjet

05-10-2011, 09:24 PM

Thanks, I will be following. Everything has to come off the top of my engine to do the coolant manifold repair.

SH || NC

05-11-2011, 08:54 AM

Also, just as a note to everyone, these types of posts are very educational for most of us, and as long as vendors (who are enthusiasts like us) keep sharing technical information with the community and avoid engaging in direct sales activities, such as listing prices for products or services, or just trying free advertising, I welcome their participation in our community. +1!

Can't wait to see the next batch of updates!

Dell

05-11-2011, 10:26 AM

Saw it over on Rennlist. Will follow here as well. SUBSCRIBED!

IPB-Autosport

05-11-2011, 11:28 PM

Oil pump and shaft are out.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TcteOccBnpI/AAAAAAAAAbg/-vxdl7hrQvY/s800/44.jpg
https://lh3.googleusercontent.com/_PCzAS4nZTAE/TcteN8H4nlI/AAAAAAAAAbY/RlOPecdx0E0/s800/42.jpg

Note the dual pick-ups on the oil pump.

https://lh3.googleusercontent.com/_PCzAS4nZTAE/TcteOHFHWlI/AAAAAAAAAbc/4QQCjnmnLQE/s800/43.jpg

Crank comes out with the rods.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TcteOyjfo-I/AAAAAAAAAbk/psYCv5zyPbQ/s800/45.jpg
https://lh5.googleusercontent.com/_PCzAS4nZTAE/TctePUfsWHI/AAAAAAAAAbo/4laZZGUIE18/s800/46.jpg

All bearings are pulled and a bare case half remains on the engine stand.

https://lh4.googleusercontent.com/_PCzAS4nZTAE/TctePk3i8zI/AAAAAAAAAbs/s0OmQth70fc/s800/47.jpg

Sleeves are pounded out with a rubber mallet out of the cylinders.

https://lh4.googleusercontent.com/_PCzAS4nZTAE/TcteP8ndHwI/AAAAAAAAAbw/i7_oam6gfPw/s800/48.jpg

Case and cylinders are pressure washed. Nice and shiny. Although, getting all the cosmoline off the exterior will take additional effort.

https://lh4.googleusercontent.com/_PCzAS4nZTAE/TcteQd_fh2I/AAAAAAAAAb4/2NbpLSC6s8s/s800/49.jpg
https://lh6.googleusercontent.com/_PCzAS4nZTAE/TcteQ4uXRUI/AAAAAAAAAb8/PDYIw-Ob-Ho/s800/50.jpg

Here’s the interesting part. Note the recesses in the cylinders to accommodate the coolant. The sleeves maintain an opposite profile. When the machinist bores out the sleeve mating surfaces for the larger 4 liter sleeves (at the tops and bottoms), the rough cast surface will also need to be bored to maintain an adequate coolant passage and prevent flow restriction. The 2 rubber gaskets in the cylinders prevent the coolant and oil from mixing. An additional gasket is located at the top of the sleeve.

https://lh5.googleusercontent.com/_PCzAS4nZTAE/TcteRFRpSOI/AAAAAAAAAcA/oKZV-HFt6FA/s800/52.jpg
https://lh4.googleusercontent.com/_PCzAS4nZTAE/TcteQHuMJ4I/AAAAAAAAAb0/svU07qPJT7s/s800/51.jpg

FTS

05-12-2011, 08:46 AM

I am first to admit I don't understand engines, a big mistery to me. All these parts coming together precisely to work at 8500 RPM reliably for thousands of miles, amazing engineering. And not to mention brave souls pulling it apart to redo, my hats off to you :D

FFaust

05-16-2011, 09:36 PM

Nice, waiting for the rest.

IPB-Autosport

05-20-2011, 12:01 AM

An old 930 flywheel is bolted up to the crank so we can place it into a vice and remove the con rods.

https://lh4.googleusercontent.com/_PCzAS4nZTAE/TdXyp-tTb6I/AAAAAAAAAcY/D5fhespFA9k/s800/53.jpg

Out they go.

https://lh4.googleusercontent.com/_PCzAS4nZTAE/TdXyqe-9wsI/AAAAAAAAAcg/U-Nw3MYYb9Y/s800/54.jpg

Bare crank.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TdXyqDSIQEI/AAAAAAAAAcc/FB_DzISVahc/s800/55.jpg

While we are waiting for pistons and sleeves to be shipped, we start working on the gearbox. Onto the stand it goes.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TdXyq7jVTDI/AAAAAAAAAck/r7hDLS9_8L4/s800/56.jpg
https://lh4.googleusercontent.com/_PCzAS4nZTAE/TdXyrNc2jWI/AAAAAAAAAco/ERWGME8eVFI/s800/57.jpg

Drain plug is pulled and oil drained. Looks like it’s doing its job.

https://lh3.googleusercontent.com/_PCzAS4nZTAE/TdXyrc1cx7I/AAAAAAAAAcs/4-s62siwSGs/s800/58.jpg

Output shafts are pulled.

https://lh5.googleusercontent.com/_PCzAS4nZTAE/TdXyr0Ek7EI/AAAAAAAAAcw/GwfOkRe2G_c/s800/59.jpg
https://lh6.googleusercontent.com/_PCzAS4nZTAE/TdXysMiQu_I/AAAAAAAAAc0/uZJZHCdVv44/s800/60.jpg

So is the differential cover. LSD is out and you can see the huge pinion gear .

https://lh5.googleusercontent.com/_PCzAS4nZTAE/TdXysSrWojI/AAAAAAAAAc4/tV59iCnMOUw/s800/61.jpg

We are ordering LSD rebuild parts from the now world-known Guard Transmission. LSD will be rebuilt once we receive parts from Matt.

https://lh3.googleusercontent.com/_PCzAS4nZTAE/TdXys0vaZwI/AAAAAAAAAc8/6SGrWr-5M0k/s800/62.jpg

IPB-Autosport

05-24-2011, 11:53 PM

Pistons and cylinder sleeves (left) for the 4 liter conversion are finally in. Mahle 105.4mm pistons, steel cylinder sleeves out of the UK from a Formula 1 supplier, stronger wrist pins, and Mahle ring sets. Pistons and sleeves were developed and sold by Wrightwood Racing in Southern California.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TdyIA9iuTYI/AAAAAAAAAe0/7hfkz4QD0MQ/s800/72.jpg

One look at the new piston (left) and you know it’s all business.

https://lh4.googleusercontent.com/_PCzAS4nZTAE/TdyH_qiFuoI/AAAAAAAAAeg/loYgSijyTT4/s800/73.jpg
https://lh4.googleusercontent.com/_PCzAS4nZTAE/TdyH_9_wsbI/AAAAAAAAAfQ/qllH9xZSdrI/s800/74.jpg
https://lh4.googleusercontent.com/_PCzAS4nZTAE/TdyIABLL0PI/AAAAAAAAAeo/H-nkfZiJa-0/s800/75.jpg

The 4 liter sleeves are a work of art themselves. They are finned in the cooling channels to provide greater surface area for heat conduction. More power requires better cooling.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TdyH-3uWyVI/AAAAAAAAAeY/30gK4iS8Xs4/s800/77.jpg
https://lh6.googleusercontent.com/_PCzAS4nZTAE/TdyH_OhB1GI/AAAAAAAAAec/31uLHoPCRQQ/s800/78.jpg

Wrist pins are heavy duty.

https://lh4.googleusercontent.com/_PCzAS4nZTAE/TdyIASfaYYI/AAAAAAAAAes/RZ7UBNlfxn8/s800/79.jpg

Piston rings from Mahle. Only the best here.

https://lh6.googleusercontent.com/_PCzAS4nZTAE/TdyIAnA39hI/AAAAAAAAAew/IjoGdX0M4_c/s800/80.jpg

The case and cylinder housings go for machining this Thursday at How Tek in Cameron Park. The owner, Howard, was the machinist for Comptech racing.

Meanwhile, we are waiting for new clutches from Guard Transmission to rebuild the limited slip differential.

FTS

05-24-2011, 11:57 PM

Side by side the difference is dramatic, super pics, thank you.

FFaust

05-25-2011, 08:27 PM

Pity to hide those parts on the "inside".

IPB-Autosport

06-08-2011, 03:34 PM

Guard LSD parts arrived. Let’s go.

Ring gear comes out.

https://lh3.googleusercontent.com/-ClU10nUOOyc/Tdc0T2VIMrI/AAAAAAAAAdU/UKLSwPWWyQE/s800/63.jpg
https://lh6.googleusercontent.com/-tSw50n1uXUE/Tdc0Uf4tYQI/AAAAAAAAAdY/BwVrBvEuVQY/s800/64.jpg

Time to split the housing.

https://lh5.googleusercontent.com/-cyPnOOiz5y8/Tdc0Uq3LXaI/AAAAAAAAAdc/ud35SLBeuKU/s800/65.jpg
https://lh5.googleusercontent.com/-iu88i5CQYCs/Tdc0VIZZnoI/AAAAAAAAAdg/pjnN-4Np2bs/s800/66.jpg

Out come the guts.

https://lh3.googleusercontent.com/-4s7wFM_P-Bk/Tdc0VYXWX3I/AAAAAAAAAdk/NMukQQYXs4I/s800/67.jpg

Oops. Serge's beer gets in the way of our photos.

https://lh5.googleusercontent.com/-zdOw033lUU8/Tdc0VkHD6CI/AAAAAAAAAdo/k6wrf5rDvFw/s800/68.jpg

This measurement determines the thicknesses of the friction disc spacers to achieve the correct preload.

https://lh6.googleusercontent.com/-glXFzPjkfiw/Tdc0WYNljfI/AAAAAAAAAds/cjjiA_ZH45U/s800/69.jpg

Spider gears.

https://lh4.googleusercontent.com/-mV3zJLj6qBs/Tdc0Xrb27sI/AAAAAAAAAd4/1ufKBbl9xs4/s800/71.jpg

Guard rebuild parts.

https://lh5.googleusercontent.com/-axm_MI8WZ1A/Te_UOnlrGbI/AAAAAAAAAfw/GxQo1Shg7FQ/s800/81.jpg

OEM vs Guard.

https://lh3.googleusercontent.com/-Lvm4h7mnkjc/Te_UPPgnk1I/AAAAAAAAAf0/btngwVZH4sw/s800/82.jpg
https://lh3.googleusercontent.com/-NYRhWwnTD6k/Te_UP7DsLBI/AAAAAAAAAf4/zRhaXXndk5E/s800/83.jpg
https://lh3.googleusercontent.com/-U2kj5h1arJo/Te_UQPCzQaI/AAAAAAAAAf8/d3y0A31JVGc/s800/84.jpg

Friction disc spacers.

https://lh5.googleusercontent.com/-sd3ocKnUFVk/Te_UQjv7V_I/AAAAAAAAAgA/AStB2o93IR4/s800/85.jpg

Belleville washers. You can see that the Guard parts have more curvature and greater thickness to achieve a higher spring rate.

https://lh5.googleusercontent.com/-Agxma5wbP1E/Te_URNFp84I/AAAAAAAAAgE/kX4pEt4GD5g/s800/86.jpg

LSD is held in place with the aid of the output flange and a vice. We actually had to fix the upper flange as well to achieve the 148 ft/lb required. Although, the preload alone almost did the job.

https://lh6.googleusercontent.com/-LYeaFb5UMh8/Te_UUcH5k4I/AAAAAAAAAgQ/-ISjdLWZp7Y/s800/87.jpg
https://lh6.googleusercontent.com/-Kw5GXt_ON70/Te_UUmmYLeI/AAAAAAAAAgU/DGOmf-QNE9s/s800/88.jpg

Rebuilt unit.

https://lh4.googleusercontent.com/-E9Hx5ZG_VT4/Te_URqZyz8I/AAAAAAAAAgI/HQpOkGkCblc/s800/89.jpg

TRAKCAR

06-09-2011, 01:06 PM

Thanks for posting. Now I know what it all looks like ..

FTS

06-09-2011, 01:53 PM

^^^ +1, excellent thread and documentation.

kristap

06-10-2011, 06:58 AM

Thanks for documenting like this!

IPB-Autosport

06-22-2011, 12:56 AM

Christmas came early! What do we have here…

https://lh4.googleusercontent.com/-7VIKgpx-J1o/TgF-Y0Y7kUI/AAAAAAAAAhk/IUK-PKRys4Y/s800/104.jpg

997 Cup heads!

https://lh5.googleusercontent.com/-cLdkAe-ZrQY/TgF-Wup9T6I/AAAAAAAAAg8/l9xflYgb9Qw/s800/92.jpg
https://lh4.googleusercontent.com/-_EVIPf9_BA0/TgF-W4WjUyI/AAAAAAAAAhA/HNDHB_JQhPQ/s800/93.jpg
https://lh5.googleusercontent.com/-b5la45K42E4/TgF-W-xcM3I/AAAAAAAAAhE/sOuwtop9ANM/s800/94.jpg

997 cup intake port.

https://lh4.googleusercontent.com/-rBVQjvuRxao/TgF-XJQS5JI/AAAAAAAAAhI/Mbr6HcGSn6E/s800/96.jpg

996 street intake port.

https://lh6.googleusercontent.com/-Kb-LWyB6vNY/TgF-Xd4jpUI/AAAAAAAAAhM/-2f5QQ7hS2Y/s800/97.jpg

Close up comparison.

https://lh4.googleusercontent.com/-e0sFbDnMBWE/TgF-XkZgPxI/AAAAAAAAAhQ/JRUvHGvdkT4/s800/95.jpg

Exhaust side.

https://lh5.googleusercontent.com/-IgEG7qMugLI/TgF-X1b4zmI/AAAAAAAAAhU/4Q4_Jt5IPM8/s800/98.jpg

997 exhaust ports.

https://lh6.googleusercontent.com/-z1AxAD_U0Ls/TgF-YB3sqPI/AAAAAAAAAhY/UPdgumnYRpY/s800/99.jpg

996 exhaust ports. Not much to see here…

https://lh5.googleusercontent.com/-MOodjHePvd8/TgF-YXGOcRI/AAAAAAAAAhc/qP3nBHDJPuE/s800/100.jpg

Side by side.

https://lh6.googleusercontent.com/-uA4EOga4VZ8/TgF-YrLSu_I/AAAAAAAAAhg/R7iG6BkaFyA/s800/101.jpg

Parts for a full engine rebuild, including the oversized gaskets for the 4 liter.

https://lh6.googleusercontent.com/-GjyRVF7OnH4/TgF-ZppW6LI/AAAAAAAAAhs/PcydZHb73T0/s800/103.jpg

ARP rod bolts, of course.

https://lh6.googleusercontent.com/-gsyBxheC9T8/TgF-ZCLk_uI/AAAAAAAAAho/YgdUE6DPlks/s800/102.jpg

PJS

06-24-2011, 02:14 PM

Subscribed

Chubby inducing thread

FTS

06-25-2011, 09:19 AM

Ron, this is superb, the comparative pictures are so clear and self-explanatory that I cannot get enough, just superb. Thank you for this post, documentation and explanations, very much appreciated.

IPB-Autosport

06-30-2011, 03:30 PM

The machine shop.

https://lh6.googleusercontent.com/-fYbr7T0sIYs/TgzYMg9TcmI/AAAAAAAAAjI/jNr5gRrMIC8/s800/105.jpg

https://lh6.googleusercontent.com/-jTkczlz5hBo/TgzYGJWtgLI/AAAAAAAAAic/fYLR9FEs-J0/s800/106.jpg

They do a lot of work for Flying Lizard Motorsports. When I was picking up my parts, he was modifying some RSR sway bar arms. Here are some brake hats in process for the Lizards.

https://lh6.googleusercontent.com/-QeViAKyDFMk/TgzYFw1G20I/AAAAAAAAAiY/LhkmU4Grcio/s800/107.jpg

The machined case. The sleeves extend about an inch into the case so it had to be opened up for accommodate the 4.0 liter sleeves.

https://lh5.googleusercontent.com/-usqYXe0bePc/TgzYGCAUuXI/AAAAAAAAAig/IqUWGn6MyHA/s800/108.jpg
https://lh3.googleusercontent.com/-g6efnGy6mpM/TgzYGbtxUPI/AAAAAAAAAio/b4wxl4zSitE/s800/109.jpg

Here’s the cylinder head and case mated together. The machining process was such that it provides a seamless transition from the cylinder housings to the case.

https://lh3.googleusercontent.com/-0WT6QQ4CDDE/TgzYGsaUt6I/AAAAAAAAAik/5uqyFOAvZvs/s800/110.jpg
https://lh6.googleusercontent.com/-eEmsDFAigUc/TgzYG__eziI/AAAAAAAAAiw/WM-obgY68NI/s800/111.jpg

4.0 sleeves are test fitted.

https://lh4.googleusercontent.com/-nxsMd-L3fDo/TgzYG1dMS9I/AAAAAAAAAis/1w8qR8mBSwQ/s800/112.jpg
https://lh6.googleusercontent.com/-3BDUV6FQ-hQ/TgzYHPmNL0I/AAAAAAAAAi0/VTSJjFtP6uI/s800/113.jpg

Here you can closely see the finish of the Nikasil coating on the cylinder walls.

https://lh3.googleusercontent.com/-a0ictKOJCBM/TgzYHPxeGMI/AAAAAAAAAi4/auYuPF-PLj0/s800/114.jpg

While waiting for the machine work to be completed, the coolant pipes were welded. As many of you know, the glued pipe interface has become a well documented Achilles heal of the GT1 engine. The welding isn’t going to win any beauty contests, but is functional.

https://lh6.googleusercontent.com/-_5sBfXiR-Mc/TgzYHdsUI5I/AAAAAAAAAi8/O1EGbDXaGEE/s800/115.jpg
https://lh3.googleusercontent.com/-ReuB3VvoekY/TgzYHRVloiI/AAAAAAAAAjA/M8S3u9yNWUI/s800/116.jpg
https://lh5.googleusercontent.com/-Q3oSNownxQY/TgzYHhfapuI/AAAAAAAAAjE/HUdmZvSd6dM/s800/117.jpg

FTS

06-30-2011, 11:39 PM

I hope this is not a stupid question, but Ron, do you have a target compression ration for this at this time, or will that be determined at a later time during tuning? I am trying to understand how the compression ratio targets impact the design, and later on, the details of machine of the case.

IPB-Autosport

07-01-2011, 11:17 PM

Compression ratio will be increased at the rod/piston connection: the wrist pin. Since these wrist pins have a smaller overall diameter, this allows us to offset the hole in the wrist pin bushing. This bring the piston further up, reducing the volume of the combustion chamber. The target is 12.5:1.

-Serge

csmarx

07-02-2011, 12:41 AM

Nice project! Wonderful to follow along with all the pictures. Thank you!

IPB-Autosport

07-26-2011, 03:56 PM

Rods are in.

https://lh3.googleusercontent.com/-kF8nXz3-CyY/Ti8oThr5T6I/AAAAAAAAAlU/j3eeJZxmRPA/s800/118.jpg
https://lh5.googleusercontent.com/-3BD2tlipcKo/Ti8oTuHDhoI/AAAAAAAAAlQ/q3ehTAYHOxU/s800/119.jpg

New rod bearings.

https://lh4.googleusercontent.com/-BUAX90XZ6iA/Ti8oTzj9W7I/AAAAAAAAAlY/y7P_IbTLby4/s800/120.jpg

Everything lubed.

https://lh6.googleusercontent.com/-M5WW3yXL238/Ti8oUPdiSRI/AAAAAAAAAlc/DdWSFT_uX50/s800/121.jpg

Assembly time.

https://lh5.googleusercontent.com/-5Xiel4k9HKE/Ti8oUEcVKLI/AAAAAAAAAlg/hGGqfgdMaF4/s800/122.jpg

New oversized bushings to accommodate the 21mm wrist pins.

https://lh4.googleusercontent.com/-IGLqCm0u6KY/Ti8oUeWPxrI/AAAAAAAAAlk/EAqZVmYVlCU/s800/123.jpg

And the engine build is on its way…

FTS

07-26-2011, 03:57 PM

Very interesting; what kind of inner sleeves are those on the rod bearings?

IPB-Autosport

07-29-2011, 05:57 PM

Case cleaned and ready to go. Main and intermediate shaft bearings go in, followed by the crankshaft assembly.

https://lh5.googleusercontent.com/-v4Mfy82izVI/TjM30YfEcOI/AAAAAAAAAm0/oeewUgQ1Ljk/s800/124.jpg

Crank is in. Porsche coat hanger special tool supports the new timing chains. Oil pump is also in.

https://lh5.googleusercontent.com/-VienxbnKMCk/TjM30vkDRcI/AAAAAAAAAm8/v8LjH9hKVR4/s800/125.jpg
https://lh3.googleusercontent.com/-V6t6fOg3f6A/TjM30XrGZCI/AAAAAAAAAm4/70ANNCivrrI/s800/126.jpg

Tensioning the oil pump nuts.

https://lh4.googleusercontent.com/-zp8Aq8_iQQE/TjM30zUptMI/AAAAAAAAAnA/-4Ie6fjcJ-c/s800/127.jpg

Time to glue the case.

https://lh5.googleusercontent.com/-V4lQa8NFKIw/TjM308D2LFI/AAAAAAAAAnI/LARZjZtk6kg/s800/128.jpg

Cleanliness is the key to getting a perfect seal.

https://lh5.googleusercontent.com/-odUxyjImKJc/TjM304WmhHI/AAAAAAAAAnE/auZWWte9aJc/s800/129.jpg
https://lh4.googleusercontent.com/-yexV6lnbrc8/TjM31HhkNYI/AAAAAAAAAnM/UsSwNcJzaTs/s800/131.jpg

Spread it with a brush.

https://lh6.googleusercontent.com/-U-VUksSkfO8/TjM31EYib0I/AAAAAAAAAnQ/DgSvDchXIQk/s800/130.jpg

Other case half is on.

https://lh6.googleusercontent.com/-b2lBHo6UgPs/TjM31OZuLPI/AAAAAAAAAnU/ZApegNaGKTo/s800/132.jpg

Special tools are required to properly seat the through-bolt seals.

https://lh3.googleusercontent.com/-okvTPJUj7wI/TjM31WAiHKI/AAAAAAAAAnY/D11V47xCclw/s800/133.jpg

The through bolts are tensioned.

https://lh4.googleusercontent.com/-ucGfX2LyHYk/TjM31bUfETI/AAAAAAAAAnc/IToS7tbMOEE/s800/134.jpg

Then the nuts around the case perimeter.

https://lh6.googleusercontent.com/-uIgcg1mKTHA/TjM31gL8tEI/AAAAAAAAAng/HNJwJoRa0TU/s800/135.jpg

The case is now put together. Next step… pistons.

IPB-Autosport

09-20-2011, 12:13 AM

The center piston is attached to the rods first… The outer pistons are inserted into the liners before attachment to the rods. Unfortunately, with non OEM size pistons or wrist pins, the factory tools are useless. This is where the challenge is.

https://lh6.googleusercontent.com/--DzMRuM1WCo/TngbgZy4PnI/AAAAAAAAAoI/hcZjW5gbEFU/s800/136.jpg

The housing is slid on with the outer two liners already in.

https://lh6.googleusercontent.com/-cZ_UR_76JkE/TngbgYyg2MI/AAAAAAAAAoE/sHtxIP4nvRc/s800/137.jpg

Of course the cylinders are stuffed to prevent the wrist pin clip from falling into the engine as you struggle to attach it.

https://lh3.googleusercontent.com/-cHJidtuwoL0/Tngbgquk58I/AAAAAAAAAoM/zuHSop4Oj9I/s800/138.jpg
https://lh3.googleusercontent.com/-cpHD-aAIGHE/TngbgsU4wTI/AAAAAAAAAoQ/IZ_snnv89JY/s800/139.jpg

At least you can use the factory tool to slide the inner sleeve in. Let me reiterate how difficult it was to get these rings in. Extra hands were necessary.

https://lh3.googleusercontent.com/-JtCWWQIr1b4/TngbgzyLf5I/AAAAAAAAAoU/FzTfYWWLljI/s800/140.jpg
https://lh5.googleusercontent.com/-fRkSWv0ksZc/TngbhDVUwdI/AAAAAAAAAoY/re3Go7uH2aA/s800/141.jpg

One bank done, on to the next one.

https://lh6.googleusercontent.com/-6Hw4bUf0PLM/TngbhNhBhnI/AAAAAAAAAoc/1ZLc5fCQofw/s800/142.jpg
https://lh6.googleusercontent.com/-DFRcXWlME4s/TngbhCsJpsI/AAAAAAAAAog/VaFgMcceqyM/s800/143.jpg
https://lh5.googleusercontent.com/-hCMozqyKDUo/TngbhQfXC7I/AAAAAAAAAok/_zsk1iuO9ew/s800/144.jpg

Center sleeve to go…

https://lh6.googleusercontent.com/-lrPNTpJFOxo/Tngbhkd3ZzI/AAAAAAAAAoo/zOsVReaJ3-8/s800/145.jpg
https://lh6.googleusercontent.com/-ajJBGqLQwLk/Tngbhr5_ceI/AAAAAAAAAos/Qle4bO4vCFA/s800/146.jpg

In frustration, time to do something easy. Chain housings and guides.

https://lh6.googleusercontent.com/-wirXL3Ti4_A/Tngbh902cvI/AAAAAAAAAow/-jGLHOIxjJw/s800/147.jpg
https://lh4.googleusercontent.com/-f4cslyqMaXM/TngbiCpL0lI/AAAAAAAAAo0/gBC7uT235mI/s800/148.jpg

Last one to go…

https://lh4.googleusercontent.com/-Xj7u2TkYAsM/TngbiWcaU1I/AAAAAAAAApE/ys5qnQxgU_s/s800/151.jpg

All pistons are in as of 8pm tonight. Thank god.

https://lh6.googleusercontent.com/-Fv_4qOZf5ME/TngbijHj6UI/AAAAAAAAApA/K7FBF8Rs4hQ/s800/152.jpg
https://lh5.googleusercontent.com/-uLPYint4PB0/Tngbi3PBOrI/AAAAAAAAApI/icU-aS_DbhQ/s800/153.jpg

In the meantime…I had my stock 996 intakes port matched to the 997 cup heads.

https://lh4.googleusercontent.com/-9hmNiedfkhc/Tngbi5hMVGI/AAAAAAAAApM/DPHCklmW2Vc/s800/154.jpg
https://lh3.googleusercontent.com/-MzeXZ7fux3w/TngbjKLaDxI/AAAAAAAAApQ/_i96KD3-OeA/s800/155.jpg
https://lh3.googleusercontent.com/-t2rzSFOaSk4/TngbjMtmjWI/AAAAAAAAApU/4secAoBskvU/s800/156.jpg

996 intake plenum. Note that this will NOT be replaced with the snake oil IPD intake.

https://lh3.googleusercontent.com/-MYNepbpkBFg/TngbjV1xxwI/AAAAAAAAApY/oqURrkTPnGw/s800/157.jpg

And the 997 throttle body just came in today too!

https://lh5.googleusercontent.com/-NQXpruNKO5k/TngbjQjvv0I/AAAAAAAAApc/uNaUsyytkcQ/s800/158.jpg

997 throttle body measures in at 84mm.

https://lh6.googleusercontent.com/-zlEa_JjfmEA/TngbjyrOQNI/AAAAAAAAApk/-m0OzOV_Ipk/s800/159.jpg

996 plenum is only 78mm. Back to the machine shop…

https://lh4.googleusercontent.com/-Wqbxc4YRjAI/TngbjidRe9I/AAAAAAAAApg/5gTKqIdT0pA/s800/160.jpg

IPB-Autosport

09-22-2011, 10:45 AM

Time to install the cam housings. On top of new seals between the chain housings and cam housings, a layer of Drei Bond is applied to ensure there are no leaks.

https://lh3.googleusercontent.com/-ZU2pzpo9qjQ/TntS5df-0QI/AAAAAAAAAp0/imXvMpuHufM/s800/161.jpg

Brand new lifters (tappets) are soaked in Swepco and positioned.

https://lh4.googleusercontent.com/-tDjH6ggpDac/TntS54Pt0HI/AAAAAAAAApw/U0gNGhEHa0s/s800/162.jpg

Cams are placed with the cylinder 1 lobes on the exhaust and intake cams facing each other. The crank is just off TDC. Porsche special tool is utilized to prevent the chain from falling in.

https://lh3.googleusercontent.com/-DKDDWFRf00A/TntS5SgySgI/AAAAAAAAAps/VAeEr163n9k/s800/163.jpg

Cam gears are positioned onto the cams. This is where we realize we received Cup intake cam bolts, which are half the length (no variable valve timing on cup). We will time bank 1 once we get the bolts and then move on to bank 2.

https://lh4.googleusercontent.com/-paoiVG2kpUE/TntS5diLtCI/AAAAAAAAApo/lQ8aVfRBK6A/s800/164.jpg

We’re getting close to having a complete long block.

FTS

09-22-2011, 10:47 AM

Thank you once again for all the information. How much of a difference will there be in the engine mounting points do you think and will there be any modifications to the engine bay to fit it?

IPB-Autosport

09-22-2011, 03:34 PM

The engine will fit just as it did before. Once it's all put together, there really won't be any visual cues that identify it as not stock.

ninerguru

09-26-2011, 05:32 PM

Any progress? DO keep us posted... Thanks!

IPB-Autosport

11-23-2011, 10:31 AM

Haven't had a chance to keep this thread up to date, but we just recently had the engine's first start up:

http://www.youtube.com/watch?v=d-Js9-BAJ64

csmarx

12-17-2011, 02:03 AM

How's the project going? Is the car driving yet? How is it? Curious car nuts wanna know!

-Christian