Pelican Parts
Parts Catalog Accessories Catalog How To Articles Tech Forums
Call Pelican Parts at 888-280-7799
Shopping Cart Cart | Project List | Order Status | Help



Go Back   Pelican Parts Forums > Porsche Forums > 911 / 930 Turbo & Super Charging Forum


Reply
 
LinkBack Thread Tools Rating: Thread Rating: 1 votes, 5.00 average.
Author
Thread Post New Thread    Reply
Registered User
 
Join Date: Sep 2002
Location: Westchester County, NY
Posts: 1,703
Garage
And as promised, the Not Safe For Work (NSFW) porn shot. Hide the children
I've been remiss in posting some pics of Brian and Ben's handiwork. Christmas arrived 4 weeks early to NY, and I simply had to simply dive in and start spinning wrenches.

The pics don't do the parts justice. There is a palpable quality level here that is similiar to what you might experience with a nice firearm... snick-snick. The welds are not like anything I've seen. I have an argon/CO2 welder and I used to claim that I knew how to weld. I realize now I do NOT know how to weld. The packaging was top-notch, the parts are US made, and the service has been excellent. I'm stoked to try them out.

__________________
1986 930, 1969 Mach1, 2003 540 Sport, 2016 R1200RS
Old 12-01-2009, 08:09 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #21 (permalink)
Crotchety Old Bastard
 
RarlyL8's Avatar
 
Join Date: Jan 2000
Location: Huntsville, AL
Posts: 13,576
Garage
Good progress. You'll get that stud out.
Did you receive the instructions? I'll go through it with you if there is anything that you get hung up on. First thing is to remove all the band clamps except the large one on the muffler. Lots of wiggling to get everything perfectly where you want it to be.
__________________
RarlyL8 Motorsports / M&K Exhaust - 911/930 Exhaust Systems, Turbos, TiAL, CIS Mods/Rebuilds
'78 911SC Widebody, 930 engine, 915 Tranny, K27, SC Cams, RL8 Headers & GT3 Muffler. 350whp @ 0.75bar
Brian B. (256)536-9977 Service@MKExhaust Brian@RarlyL8
Old 12-01-2009, 08:43 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #22 (permalink)
Registered User
 
Join Date: Sep 2002
Location: Westchester County, NY
Posts: 1,703
Garage
OK, that didn't go too well. Despite using a stud extractor kit specifically for 8mm, and heating up the head around the stud, the tool snapped the stud. Actually, it snapped it twice... once it broke with about 1/2" remaining, and then it snapped again flush with the head. A series of left handed bits and extractor work was employed to no effect. Despite a center punch, I was unable to nail the 10x ring on the stud, and the hole is slightly off, but I was still able to slide Brian's header on over the studs during a testfit with a replacement stud in the hole.
I'm left with a 5/16ths hole so far, and researching 8mm time serts. Do I have enough room around the hole to drill and tap for the much larger timesert?


I also had similarly miserable time with the wastegate. I am now left four 5/16ths drilll holes similar to the one in the cylinder head above. Do you think I have enough meat to put the time serts here, too?


Won't be sorry not to see these particular tools for a long time-

__________________
1986 930, 1969 Mach1, 2003 540 Sport, 2016 R1200RS
Old 12-06-2009, 01:09 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #23 (permalink)
Registered User
 
Join Date: Sep 2002
Location: Westchester County, NY
Posts: 1,703
Garage
Oh, and I am traveling for work for the next two weeks so in any scenario, this job can't be picked up until around Christmas. At least I have that week between the two holidays to knock this job off completely.
Here's the time sert link I have been looking at, and figure on getting the 8mm x 1.25 set.


++ TIME-SERT Metric Kits ++ thread repair kits and inserts repair stripped threads damaged threads repaired threads threaded inserts for metal thread inserts for metal aluminum inserts threaded inserts for aluminum

Thoughts welcome
__________________
1986 930, 1969 Mach1, 2003 540 Sport, 2016 R1200RS
Old 12-06-2009, 01:15 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #24 (permalink)
Registered User
 
sjf911's Avatar
 
Join Date: Dec 2006
Location: Idaho
Posts: 5,624
Garage
Someone on the board makes and sells a simple exhaust stud extractor jig that preserves the original 8mm thread in the head. Do a search or ask around if anyone has one they can loan you.
__________________
Steve
Sapere aude
1983 3.4L 911SC turbo. Sold
Old 12-06-2009, 02:07 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #25 (permalink)
Registered User
 
Join Date: Aug 2008
Location: CA
Posts: 181
Ive done the time sert install and used p/n 1812. They cost about 100 bucks and come with enough parts to repair 5 studs, which looks like the perfect amount for you since you have broken 4 wastegate studs and 1 exhaust stud. The kit is pretty easy to use, just follow the directions.
Old 12-06-2009, 04:09 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #26 (permalink)
Crotchety Old Bastard
 
RarlyL8's Avatar
 
Join Date: Jan 2000
Location: Huntsville, AL
Posts: 13,576
Garage
Wow, has this engine never been rebuilt? You really are doing a worst case scenario exhaust removal.
__________________
RarlyL8 Motorsports / M&K Exhaust - 911/930 Exhaust Systems, Turbos, TiAL, CIS Mods/Rebuilds
'78 911SC Widebody, 930 engine, 915 Tranny, K27, SC Cams, RL8 Headers & GT3 Muffler. 350whp @ 0.75bar
Brian B. (256)536-9977 Service@MKExhaust Brian@RarlyL8
Old 12-06-2009, 06:26 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #27 (permalink)
Registered User
 
9dreizig's Avatar
 
Join Date: Jul 2005
Location: Reno NV, Bay Area during most weeks,, Kids still in NH
Posts: 5,784
Send a message via AIM to 9dreizig
Quote:
Originally Posted by RarlyL8 View Post
Wow, has this engine never been rebuilt? You really are doing a great job, take your time and it will all be fine.

There fixed it for you Brian (dude don't scare the customers!! )
__________________
"Todd"
98 Tahoe ,2007 Saturn Vue
86 930 black and stock, 80 930 blue tracdog
91 Spec Miata (yeah I race a chick car)
"life"ll kill ya" Warren Zevon
Old 12-06-2009, 06:39 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #28 (permalink)
Registered User
 
9dreizig's Avatar
 
Join Date: Jul 2005
Location: Reno NV, Bay Area during most weeks,, Kids still in NH
Posts: 5,784
Send a message via AIM to 9dreizig
On a serious note,, I found this link Exhaust Stud Jig

it will lead you to the pelican who makes the jig. Or Brian, since you're now selling headers, you may want to add the jig to your quiver since alot of customers will probably want one..
__________________
"Todd"
98 Tahoe ,2007 Saturn Vue
86 930 black and stock, 80 930 blue tracdog
91 Spec Miata (yeah I race a chick car)
"life"ll kill ya" Warren Zevon
Old 12-06-2009, 06:43 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #29 (permalink)
Crotchety Old Bastard
 
RarlyL8's Avatar
 
Join Date: Jan 2000
Location: Huntsville, AL
Posts: 13,576
Garage
Hehe, yes sugar coating is not my strong suit. Ken IS doing a great job tackling these obstacles but I really think this is a great thread for all folks to see when deciding if they should remove the exhasust system themselves. Mine had been on for 10 years and came off like it was brand new. Not always that lucky.
__________________
RarlyL8 Motorsports / M&K Exhaust - 911/930 Exhaust Systems, Turbos, TiAL, CIS Mods/Rebuilds
'78 911SC Widebody, 930 engine, 915 Tranny, K27, SC Cams, RL8 Headers & GT3 Muffler. 350whp @ 0.75bar
Brian B. (256)536-9977 Service@MKExhaust Brian@RarlyL8
Old 12-06-2009, 06:46 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #30 (permalink)
Registered User
 
Join Date: Sep 2002
Location: Westchester County, NY
Posts: 1,703
Garage
This is an interesting car. It was bought in PA by a physician and he put a quick 60k on it and then sold it to another physician in CA in 92, IIRC. The first guy had some warrnaty work on the heat/ac control and had a new clutch installed just before he sold it. Other than that , it is untouched. It has good compression across the board, and doesn't puff any smoke, uses alittle oil but so what. It sat in the second MDs CA garage for 10 years, with him putting only 18k on it in those 10 years till I bought it in 2002. The one wierd thing is somewhere a k27 7006 appeared on the car and I have no receipts for that work. And as I had mentioned in my first post, someone had thoroughly wiped out one of the barrel nuts, which was also undocumented in any of the reciepts I got with the car.

So yes, the engie is untouched from what I can tell, and the exhasut system hardware appears to have spend some time on the bottom of the North Atlantic. If I had the money, I would drop it and renew the heads and address some oil leaks, and maybe get rid of the air pump spider. But for now I just want to button it back up and enjoy this new exhasut system and non-muffled wastegate dump pipe.

For others considering this job, I imagine you won't have as difficult a time as I have had unless your car lived a similar life to mine (23 years untouched). I'm lucky I have a daily driver and this thing can sit while I chase tools or parts to do the job right. I love these 930s and feel something like a steward of it. They deserve a careful approach to upkeep. They're not making any more of them!
__________________
1986 930, 1969 Mach1, 2003 540 Sport, 2016 R1200RS
Old 12-06-2009, 07:40 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #31 (permalink)
Registered User
 
Ken911's Avatar
 
Join Date: May 2005
Location: Loxahatchee, florida
Posts: 2,701
+1 on the exhaust stud tool for drilling them out. I got that kit when I rebuilt mine, it was so precise that the threads came out like a spring. So if you are planning on going with time certs (which is a good thing) I would still get the tool to make sure everything is centered correctly. Better than the risk of screwing the head up. Throw the waste gate in the trash and get a Tial or a Tial knock off. you can buy a tial knock off thats still built better than the stock one for less than 100$. Tial replacement springs are about 30$.
__________________
88 turbo Guards red Targa slant nose, and yes I am a horsepower junkie, 3.4liter,7.5 to 1 JE pistons, Adjustable WUR, Imagine fuel head, 1 bar waste gate headers,allthe cis toys. Now apart to become the next EFI monster. fabbing my own intake, headers Individual throttle bodies, MS-3, pauter rods, Xtreme twin plugged heads, gt-2 evo cams cop's.
05 Cayenne S lapis blue

Last edited by Ken911; 12-06-2009 at 08:58 PM..
Old 12-06-2009, 08:51 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #32 (permalink)
 
Manassas, VA
 
lucittm's Avatar
 
Join Date: Apr 2007
Posts: 1,211
Garage
Porsche used some pretty hard material when they spec'd the exhaust system studs. This is why they are such a pain to remove. Typically Porsche overengineered, the studs don't have to be that strong to make a good axhaust seal (when good seals are used).
You addressed removal of the stud and installation of the timesert, but you did not mention the stud replacement. You could,
1. Buy some 8mm allthread and cut it to size. (cheap and not as strong)
2. Buy the replacement studs from our sponsor ($3.00 each and OEM)
3. Buy some ARP Stainless studs and never worry about them again.

Good Luck,
Mark
__________________
1991 964 Polar Silver Metallic Turbo Coupe
Old 12-07-2009, 04:55 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #33 (permalink)
Registered User
 
Join Date: Sep 2002
Location: Westchester County, NY
Posts: 1,703
Garage
Some big steps made this weekend (in between business trips).
Time-serts are fantastic. Drill, countersink, tap, and twist in the barrel nut. Every tapping on the aluminum block and heads ought to have these. I completed the one in the cylinder head for the exhaust flange, and all four on the wastegate-to-exhaust flange.

With all the plumbing out of the way, I also removed all of the valve covers for what will be the easiest valve adjustment possible short of having the engine on a stand. It appears all my head studs are intact, which would have been the last straw and necessitated a drop.
And there she sits until my return...

Tackling this as a winter job was smart- it was snowy/icy etc here in NY so even with my crummy availability none of this has cost me any down-time.
__________________
1986 930, 1969 Mach1, 2003 540 Sport, 2016 R1200RS
Old 12-13-2009, 07:03 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #34 (permalink)
Automotive Monomaniac
 
Emission's Avatar
 
Join Date: May 2002
Location: Newbury Park, CA
Posts: 4,206
Garage
Glad to hear things are going in the right direction!

- Mike
__________________
1986 - 930 Coupe / 2016 - BMW X5 xDrive35i / 2015 - Volkswagen Golf TDI 6MT / 2018 -Porsche 911 Carrera 7MT
Old 12-13-2009, 10:19 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #35 (permalink)
Registered User
 
Join Date: Sep 2002
Location: Westchester County, NY
Posts: 1,703
Garage
progress!

Hope everyone had a nice Christmas and an even better New Years (tonight). I was able to move onto the install itself today. I used the copper nuts from our host for the exhaust studs and turbo mounting bolts.
One of the nice things about the slip fittings is that multiple adjustments can be made to make sure everything lines up nice-nice. The turbo really can move around and with the k27-7006 I have, the turbo mounting bracket is not dead on. I reinstalled the intercooler so that I could sit it squarely in the up-pipe, and then tapped the header secondary pipe turbo flange over to meet the turbo itself. Then I used the floor jack to get the turbo up 3/4" to that top left bolt with the spacer on the turbo bracket. Without the slip fittings this would not have been doable. The turbo bracket still needed Mr. Torch to cherry it up and tweak it so the lower two bolt holes lined up.

So far I've had to FedEx from Pelican twice- once for a handful of studs and nuts that I was short on, and once wehn I realized my car is missing the muffler bracket. Unfortunately I'm still waiting on that part b/c PP does not stock it.

The last thing I will point out for Brian's heat plans is that the RH side looks straightforward enough (first pic), but the LH side will require some thought. The downpipe from the fan drops right into the middle of the wastegate crossover circuit. I don't know if all fan routing for heat is the same for the different year 930s, but I will wager that on my 86 some non-stock flexible hose will have to be utilized in place of the hard drop pipe on the LH side. I can provide more pictures if necessary.




__________________
1986 930, 1969 Mach1, 2003 540 Sport, 2016 R1200RS
Old 12-31-2009, 04:08 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #36 (permalink)
Wo ist die Rennstrecke?
 
DonE's Avatar
 
Join Date: Mar 2004
Location: Brooks, GA
Posts: 1,211
In your pic above, is the secondary coming from the driver's side to the header flange just a slip joint and not welded?

For the waste gate circuit, are the two clamps just there temporarily while assembling?
Old 12-31-2009, 05:40 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #37 (permalink)
Crotchety Old Bastard
 
RarlyL8's Avatar
 
Join Date: Jan 2000
Location: Huntsville, AL
Posts: 13,576
Garage
The stock heater down pipe will not work with the heater boxes. That was a worthy compromise for the waste gate circuit. Short hoses will be required on both sides.
Yes Don the secondary is a very tight slip joint. All of the joints are precision fit and do not leak. They add an incredible amount of adjustability when compared to anything else on the market. You can move the turbo mounting point vertically and horizontally as well as front to back.
The worm clamps are for vibration resistance. Welding the waste gate pipe to the secondary pipe at that location could compromise the secondary joint. Stainless clamps are used to prevent vibration which might promote cracking over the long haul. I may come up with a more aestheticly pleasing setup but functionally this works very well as these stainless clamps are overkill for the task.
__________________
RarlyL8 Motorsports / M&K Exhaust - 911/930 Exhaust Systems, Turbos, TiAL, CIS Mods/Rebuilds
'78 911SC Widebody, 930 engine, 915 Tranny, K27, SC Cams, RL8 Headers & GT3 Muffler. 350whp @ 0.75bar
Brian B. (256)536-9977 Service@MKExhaust Brian@RarlyL8
Old 12-31-2009, 08:47 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #38 (permalink)
Registered User
 
Join Date: Sep 2002
Location: Westchester County, NY
Posts: 1,703
Garage
Started the car today and I hope to get it on the ground and provide some driving impressions tomorrow. It sounds pretty scrappy at idle! I don't have the bumper back on yet as I've taken the opportunity to remove the large rubber blocks from it and need to install a lighted license plate frame that hopefully arrives today.

However- I have noticed that my wastegate leaks out exhaust at ide! As I was going around checking for leaks etc I noticed that it was puffing out the dump pipe- I covered it with my hand and of course it quiets down. All I can think of right now is that perhaps the valve face isn't seating properly on the square valve seat after my time-sert work? Need to get back under there and see if lossening and snugging the WG to WG flange improves anything. I had tested it on the bench before the stud work and the valve did suck open at around 17psi
__________________
1986 930, 1969 Mach1, 2003 540 Sport, 2016 R1200RS
Old 01-15-2010, 10:44 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #39 (permalink)
Forced Induction Junkie
 
WERK I's Avatar
 
Join Date: Jan 2003
Location: Wisconsin
Posts: 3,291
Garage
Quote:
Originally Posted by gsxrken View Post

However- I have noticed that my wastegate leaks out exhaust at ide! As I was going around checking for leaks etc I noticed that it was puffing out the dump pipe- I covered it with my hand and of course it quiets down. All I can think of right now is that perhaps the valve face isn't seating properly on the square valve seat after my time-sert work? Need to get back under there and see if lossening and snugging the WG to WG flange improves anything. I had tested it on the bench before the stud work and the valve did suck open at around 17psi
Maybe a piece of metal filing?
Seriously, I hope it is the valve not seating and not a ruptured diaphragm.
__________________
Dave
'85 930 Factory Special Wishes Flachbau
Werk I Zuffenhausen 3.3l/330BHP Engine with Sonderwunsch Cams, FabSpeed Headers, Kokeln IC, Twin Plugged Electromotive Crankfire, Tial Wastegate(0.8 Bar), K27 Hybrid Turbo, Ruf Twin-tip Muffler, Fikse FM-5's 8&10x17, 8:41 R&P
Old 01-15-2010, 11:05 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #40 (permalink)
Reply

Thread Tools
Rate This Thread
Rate This Thread:

 


All times are GMT -8. The time now is 10:55 PM.


 
Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2018, vBulletin Solutions, Inc.
Search Engine Optimization by vBSEO 3.6.0
Copyright 2018 Pelican Parts, LLC - Posts may be archived for display on the Pelican Parts Website -    DMCA Registered Agent Contact Page
 

DTO Garage Plus vBulletin Plugins by Drive Thru Online, Inc.