IPB-Autosport 996 GT3 4 Liter
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/_P...ter%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/_P...3t8/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/_P...NOU/s800/3.jpg It’s massive. https://lh4.googleusercontent.com/_P...v8E/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/_P...gac/s800/7.jpg Clutch plate still looks good. https://lh6.googleusercontent.com/_P...ysw/s800/8.jpg Two studs are pulled and the engine is secured with allens. https://lh6.googleusercontent.com/_P...GDA/s800/5.jpg https://lh5.googleusercontent.com/_P...9wc/s800/6.jpg Out comes the oil tank and associated lines. https://lh4.googleusercontent.com/_P...QzQ/s800/9.jpg https://lh4.googleusercontent.com/_P...t4/s800/10.jpg Next the intake manifold. https://lh5.googleusercontent.com/_P...Ic/s800/11.jpg https://lh5.googleusercontent.com/_P...u0/s800/12.jpg https://lh3.googleusercontent.com/_P...lQ/s800/13.jpg https://lh3.googleusercontent.com/_P...GM/s800/14.jpg Oil cooler and cooling manifold come out. https://lh6.googleusercontent.com/_P...ZI/s800/15.jpg https://lh4.googleusercontent.com/_P...R0/s800/16.jpg Alternator and A/C compressor comes next. https://lh5.googleusercontent.com/_P...YQ/s800/17.jpg Power steering pump and reservoir. https://lh5.googleusercontent.com/_P...FQ/s800/18.jpg Water pump comes out last. https://lh4.googleusercontent.com/_P...yE/s800/19.jpg We are down to a long block. https://lh6.googleusercontent.com/_P...7Q/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/_P...sI/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/_P...yw/s800/22.jpg My engine is next to a 993 GT2 Evo 3.8. Cool, huh? https://lh3.googleusercontent.com/_P...j0/s800/23.jpg We need more motivation in this room. Ah yes, the Wurth calendar! https://lh6.googleusercontent.com/_P...dU/s800/24.jpg Cam covers come off with the motivation of big orange. https://lh5.googleusercontent.com/_P...CI/s800/25.jpg https://lh5.googleusercontent.com/_P...G8/s800/26.jpg Out come the chain tensioners. https://lh4.googleusercontent.com/_P...1A/s800/27.jpg Porsche specialty tools are used to hold the cam gears in order to loosen the nuts. https://lh3.googleusercontent.com/_P...OU/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/_P...Yk/s800/29.jpg Timing chain housings and cam housings come out. https://lh6.googleusercontent.com/_P...kc/s800/30.jpg Then the heads. https://lh3.googleusercontent.com/_P..._4/s800/31.jpg Parts lay on the work table. https://lh3.googleusercontent.com/_P...co/s800/32.jpg https://lh6.googleusercontent.com/_P...JI/s800/33.jpg Cylinders slide off exposing the pistons. https://lh6.googleusercontent.com/_P...ag/s800/34.jpg https://lh5.googleusercontent.com/_P...CM/s800/35.jpg Pistons are unclipped. https://lh5.googleusercontent.com/_P...kU/s800/36.jpg https://lh4.googleusercontent.com/_P...iI/s800/37.jpg Time to split the case. https://lh6.googleusercontent.com/_P...tQ/s800/38.jpg The engine stand is struck with a hammer to shock the case. https://lh3.googleusercontent.com/_P...oc/s800/39.jpg https://lh3.googleusercontent.com/_P...fA/s800/40.jpg The internals are beautiful. https://lh3.googleusercontent.com/_P...Rg/s800/41.jpg That's all for tonight - the past few days have been exhausting! |
Re: IPB-Autosport 996 GT3 4 Liter
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, |
Re: IPB-Autosport 996 GT3 4 Liter
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? |
Re: IPB-Autosport 996 GT3 4 Liter
Me Likey!
Can't wait to see the progress, dyno results and laptimes. Ideally with before and after overlays. That's all. |
Re: IPB-Autosport 996 GT3 4 Liter
Following with curiosity as well.
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Re: IPB-Autosport 996 GT3 4 Liter
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/porsc...onversion-kit/ |
Re: IPB-Autosport 996 GT3 4 Liter
I will be posting pics of each step along the way, as well as pics of all enhancements to improve reliability.
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Re: IPB-Autosport 996 GT3 4 Liter
Thanks, I will be following. Everything has to come off the top of my engine to do the coolant manifold repair.
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Re: IPB-Autosport 996 GT3 4 Liter
Quote:
Can't wait to see the next batch of updates! |
Re: IPB-Autosport 996 GT3 4 Liter
Saw it over on Rennlist. Will follow here as well. SUBSCRIBED!
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Re: IPB-Autosport 996 GT3 4 Liter
Oil pump and shaft are out.
https://lh6.googleusercontent.com/_P...vY/s800/44.jpg https://lh3.googleusercontent.com/_P...E0/s800/42.jpg Note the dual pick-ups on the oil pump. https://lh3.googleusercontent.com/_P...QE/s800/43.jpg Crank comes out with the rods. https://lh6.googleusercontent.com/_P...bQ/s800/45.jpg https://lh5.googleusercontent.com/_P...18/s800/46.jpg All bearings are pulled and a bare case half remains on the engine stand. https://lh4.googleusercontent.com/_P...fc/s800/47.jpg Sleeves are pounded out with a rubber mallet out of the cylinders. https://lh4.googleusercontent.com/_P...Pw/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/_P...8s/s800/49.jpg https://lh6.googleusercontent.com/_P...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/_P...FA/s800/52.jpg https://lh4.googleusercontent.com/_P...7s/s800/51.jpg |
Re: IPB-Autosport 996 GT3 4 Liter
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
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Re: IPB-Autosport 996 GT3 4 Liter
Nice, waiting for the rest.
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Re: IPB-Autosport 996 GT3 4 Liter
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/_P...9k/s800/53.jpg Out they go. https://lh4.googleusercontent.com/_P...9Y/s800/54.jpg Bare crank. https://lh6.googleusercontent.com/_P...hc/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/_P...L4/s800/56.jpg https://lh4.googleusercontent.com/_P...FI/s800/57.jpg Drain plug is pulled and oil drained. Looks like it’s doing its job. https://lh3.googleusercontent.com/_P...Gs/s800/58.jpg Output shafts are pulled. https://lh5.googleusercontent.com/_P..._c/s800/59.jpg https://lh6.googleusercontent.com/_P...44/s800/60.jpg So is the differential cover. LSD is out and you can see the huge pinion gear . https://lh5.googleusercontent.com/_P...Uw/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/_P...0k/s800/62.jpg |
Re: IPB-Autosport 996 GT3 4 Liter
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/_P...MQ/s800/72.jpg One look at the new piston (left) and you know it’s all business. https://lh4.googleusercontent.com/_P...T4/s800/73.jpg https://lh4.googleusercontent.com/_P...rI/s800/74.jpg https://lh4.googleusercontent.com/_P...-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/_P...s4/s800/77.jpg https://lh6.googleusercontent.com/_P...QQ/s800/78.jpg Wrist pins are heavy duty. https://lh4.googleusercontent.com/_P...n8/s800/79.jpg Piston rings from Mahle. Only the best here. https://lh6.googleusercontent.com/_P..._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. |
Re: IPB-Autosport 996 GT3 4 Liter
Side by side the difference is dramatic, super pics, thank you.
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Re: IPB-Autosport 996 GT3 4 Liter
Pity to hide those parts on the "inside".
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Re: IPB-Autosport 996 GT3 4 Liter
Thanks for posting. Now I know what it all looks like ..
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Re: IPB-Autosport 996 GT3 4 Liter
^^^ +1, excellent thread and documentation.
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Re: IPB-Autosport 996 GT3 4 Liter
Thanks for documenting like this!
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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. https://lh6.googleusercontent.com/-g...s/s800/102.jpg<!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:TrackMoves/> <w:TrackFormatting/> <w:PunctuationKerning/> <w:ValidateAgainstSchemas/> <w:SaveIfXMLInvalid>false</w:SaveIfXMLInvalid> <w:IgnoreMixedContent>false</w:IgnoreMixedContent> <w:AlwaysShowPlaceholderText>false</w:AlwaysShowPlaceholderText> <w:DoNotPromoteQF/> <w:LidThemeOther>EN-US</w:LidThemeOther> <w:LidThemeAsian>X-NONE</w:LidThemeAsian> <w:LidThemeComplexScript>X-NONE</w:LidThemeComplexScript> <w:Compatibility> <w:BreakWrappedTables/> <w:SnapToGridInCell/> <w:WrapTextWithPunct/> <w:UseAsianBreakRules/> <w:DontGrowAutofit/> 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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.
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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.
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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!
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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?
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Re: IPB-Autosport 996 GT3 4 Liter
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Locked="false" Priority="31" SemiHidden="false" UnhideWhenUsed="false" QFormat="true" Name="Subtle Reference"/> <w:LsdException Locked="false" Priority="32" SemiHidden="false" UnhideWhenUsed="false" QFormat="true" Name="Intense Reference"/> <w:LsdException Locked="false" Priority="33" SemiHidden="false" UnhideWhenUsed="false" QFormat="true" Name="Book Title"/> <w:LsdException Locked="false" Priority="37" Name="Bibliography"/> <w:LsdException Locked="false" Priority="39" QFormat="true" Name="TOC Heading"/> </w:LatentStyles> </xml><![endif]--><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-priority:99; mso-style-qformat:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin-top:0in; mso-para-margin-right:0in; mso-para-margin-bottom:10.0pt; mso-para-margin-left:0in; line-height:115%; mso-pagination:widow-orphan; font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin;} </style> <![endif]--> Case cleaned and ready to go. Main and intermediate shaft bearings go in, followed by the crankshaft assembly.
https://lh5.googleusercontent.com/-v...k/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/-V...4/s800/125.jpg https://lh3.googleusercontent.com/-V...I/s800/126.jpg Tensioning the oil pump nuts. https://lh4.googleusercontent.com/-z...c/s800/127.jpg Time to glue the case. https://lh5.googleusercontent.com/-V...g/s800/128.jpg Cleanliness is the key to getting a perfect seal. https://lh5.googleusercontent.com/-o...c/s800/129.jpg https://lh4.googleusercontent.com/-y...s/s800/131.jpg Spread it with a brush. https://lh6.googleusercontent.com/-U...k/s800/130.jpg Other case half is on. https://lh6.googleusercontent.com/-b...o/s800/132.jpg Special tools are required to properly seat the through-bolt seals. https://lh3.googleusercontent.com/-o...w/s800/133.jpg The through bolts are tensioned. https://lh4.googleusercontent.com/-u...E/s800/134.jpg Then the nuts around the case perimeter. https://lh6.googleusercontent.com/-u...U/s800/135.jpg The case is now put together. Next step… pistons. |
Re: IPB-Autosport 996 GT3 4 Liter
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/--...U/s800/136.jpg The housing is slid on with the outer two liners already in. https://lh6.googleusercontent.com/-c...c/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/-c...I/s800/138.jpg https://lh3.googleusercontent.com/-c...Y/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/-J...I/s800/140.jpg https://lh5.googleusercontent.com/-f...A/s800/141.jpg One bank done, on to the next one. https://lh6.googleusercontent.com/-6...w/s800/142.jpg https://lh6.googleusercontent.com/-D...M/s800/143.jpg https://lh5.googleusercontent.com/-h...w/s800/144.jpg Center sleeve to go… https://lh6.googleusercontent.com/-l...8/s800/145.jpg https://lh6.googleusercontent.com/-a...A/s800/146.jpg In frustration, time to do something easy. Chain housings and guides. https://lh6.googleusercontent.com/-w...w/s800/147.jpg https://lh4.googleusercontent.com/-f...I/s800/148.jpg Last one to go… https://lh4.googleusercontent.com/-X...s/s800/151.jpg All pistons are in as of 8pm tonight. Thank god. https://lh6.googleusercontent.com/-F...Q/s800/152.jpg https://lh5.googleusercontent.com/-u...Q/s800/153.jpg In the meantime…I had my stock 996 intakes port matched to the 997 cup heads. https://lh4.googleusercontent.com/-9...c/s800/154.jpg https://lh3.googleusercontent.com/-M...A/s800/155.jpg https://lh3.googleusercontent.com/-t...U/s800/156.jpg 996 intake plenum. Note that this will NOT be replaced with the snake oil IPD intake. https://lh3.googleusercontent.com/-M...w/s800/157.jpg And the 997 throttle body just came in today too! https://lh5.googleusercontent.com/-N...Q/s800/158.jpg 997 throttle body measures in at 84mm. https://lh6.googleusercontent.com/-z...k/s800/159.jpg 996 plenum is only 78mm. Back to the machine shop… https://lh4.googleusercontent.com/-W...A/s800/160.jpg |
Re: IPB-Autosport 996 GT3 4 Liter
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/-Z...M/s800/161.jpg Brand new lifters (tappets) are soaked in Swepco and positioned. https://lh4.googleusercontent.com/-t...s/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/-D...k/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/-p...A/s800/164.jpg We’re getting close to having a complete long block. |
Re: IPB-Autosport 996 GT3 4 Liter
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?
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Re: IPB-Autosport 996 GT3 4 Liter
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.
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Re: IPB-Autosport 996 GT3 4 Liter
Any progress? DO keep us posted... Thanks!
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Re: IPB-Autosport 996 GT3 4 Liter
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 |
Re: IPB-Autosport 996 GT3 4 Liter
How's the project going? Is the car driving yet? How is it? Curious car nuts wanna know!
-Christian |
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