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-   -   IPB-Autosport 996 GT3 4 Liter (http://gt2gt3cup.org/showthread.php?t=199)

IPB-Autosport 05-10-2011 02:10 AM

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!

FTS 05-10-2011 02:36 AM

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,

landjet 05-10-2011 05:33 AM

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?

TRAKCAR 05-10-2011 12:31 PM

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.

Trackrat 05-10-2011 12:33 PM

Re: IPB-Autosport 996 GT3 4 Liter
 
Following with curiosity as well.

cfjan 05-10-2011 12:56 PM

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/

IPB-Autosport 05-10-2011 01:11 PM

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.

landjet 05-10-2011 09:24 PM

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.

SH || NC 05-11-2011 08:54 AM

Re: IPB-Autosport 996 GT3 4 Liter
 
Quote:

Originally Posted by FTS (Post 1526)
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

Re: IPB-Autosport 996 GT3 4 Liter
 
Saw it over on Rennlist. Will follow here as well. SUBSCRIBED!

IPB-Autosport 05-11-2011 11:28 PM

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

FTS 05-12-2011 08:46 AM

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

FFaust 05-16-2011 09:36 PM

Re: IPB-Autosport 996 GT3 4 Liter
 
Nice, waiting for the rest.

IPB-Autosport 05-20-2011 12:01 AM

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

IPB-Autosport 05-24-2011 11:53 PM

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.


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