Re: IPB-Autosport 996 GT3 4 Liter
 

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

Re: IPB-Autosport 996 GT3 4 Liter
 

Pity to hide those parts on the "inside".

Re: IPB-Autosport 996 GT3 4 Liter
 

Guard LSD parts arrived. Let’s go.

Ring gear comes out.

https://lh3.googleusercontent.com/-C...QE/s800/63.jpg
https://lh6.googleusercontent.com/-t...QY/s800/64.jpg

Time to split the housing.

https://lh5.googleusercontent.com/-c...KU/s800/65.jpg
https://lh5.googleusercontent.com/-i...bs/s800/66.jpg

Out come the guts.

https://lh3.googleusercontent.com/-4...4I/s800/67.jpg

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

https://lh5.googleusercontent.com/-z...Fw/s800/68.jpg

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

https://lh6.googleusercontent.com/-g...5U/s800/69.jpg

Spider gears.

https://lh4.googleusercontent.com/-m...s4/s800/71.jpg

Guard rebuild parts.

https://lh5.googleusercontent.com/-a...FQ/s800/81.jpg

OEM vs Guard.

https://lh3.googleusercontent.com/-L...sw/s800/82.jpg
https://lh3.googleusercontent.com/-N...5E/s800/83.jpg
https://lh3.googleusercontent.com/-U...Gc/s800/84.jpg

Friction disc spacers.

https://lh5.googleusercontent.com/-s...R4/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/-A...5g/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/-L...7Y/s800/87.jpg
https://lh6.googleusercontent.com/-K...9s/s800/88.jpg

Rebuilt unit.

https://lh4.googleusercontent.com/-E...lc/s800/89.jpg

Re: IPB-Autosport 996 GT3 4 Liter
 

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

Re: IPB-Autosport 996 GT3 4 Liter
 

^^^ +1, excellent thread and documentation.

Re: IPB-Autosport 996 GT3 4 Liter
 

Thanks for documenting like this!

Re: IPB-Autosport 996 GT3 4 Liter
 

Christmas came early! What do we have here…

https://lh4.googleusercontent.com/-7...Y/s800/104.jpg

997 Cup heads!

https://lh5.googleusercontent.com/-c...Qw/s800/92.jpg
https://lh4.googleusercontent.com/-_...PQ/s800/93.jpg
https://lh5.googleusercontent.com/-b...NM/s800/94.jpg

997 cup intake port.

https://lh4.googleusercontent.com/-r...6E/s800/96.jpg

996 street intake port.

https://lh6.googleusercontent.com/-K...2Y/s800/97.jpg

Close up comparison.

https://lh4.googleusercontent.com/-e...T4/s800/95.jpg

Exhaust side.

https://lh5.googleusercontent.com/-I...M8/s800/98.jpg

997 exhaust ports.

https://lh6.googleusercontent.com/-z...pY/s800/99.jpg

996 exhaust ports. Not much to see here…

https://lh5.googleusercontent.com/-M...E/s800/100.jpg

Side by side.

https://lh6.googleusercontent.com/-u...A/s800/101.jpg

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

https://lh6.googleusercontent.com/-G...0/s800/103.jpg

ARP rod bolts, of course.

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Re: IPB-Autosport 996 GT3 4 Liter
 

Subscribed

Chubby inducing thread

Re: IPB-Autosport 996 GT3 4 Liter
 

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.

Re: IPB-Autosport 996 GT3 4 Liter
 

The machine shop.

https://lh6.googleusercontent.com/-f...8/s800/105.jpg

https://lh6.googleusercontent.com/-j...0/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/-Q...o/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/-u...A/s800/108.jpg
https://lh3.googleusercontent.com/-g...E/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/-0...s/s800/110.jpg
https://lh6.googleusercontent.com/-e...I/s800/111.jpg

4.0 sleeves are test fitted.

https://lh4.googleusercontent.com/-n...Q/s800/112.jpg
https://lh6.googleusercontent.com/-3...I/s800/113.jpg

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

https://lh3.googleusercontent.com/-a...0/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/-_...E/s800/115.jpg
https://lh3.googleusercontent.com/-R...I/s800/116.jpg
https://lh5.googleusercontent.com/-Q...M/s800/117.jpg

Re: IPB-Autosport 996 GT3 4 Liter
 

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.

Re: IPB-Autosport 996 GT3 4 Liter
 

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

Re: IPB-Autosport 996 GT3 4 Liter
 

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

Re: IPB-Autosport 996 GT3 4 Liter
 

Rods are in.

https://lh3.googleusercontent.com/-k...A/s800/118.jpg
https://lh5.googleusercontent.com/-3...U/s800/119.jpg

New rod bearings.

https://lh4.googleusercontent.com/-B...4/s800/120.jpg

Everything lubed.

https://lh6.googleusercontent.com/-M...0/s800/121.jpg

Assembly time.

https://lh5.googleusercontent.com/-5...4/s800/122.jpg

New oversized bushings to accommodate the 21mm wrist pins.

https://lh4.googleusercontent.com/-I...U/s800/123.jpg

And the engine build is on its way…

Re: IPB-Autosport 996 GT3 4 Liter
 

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