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Slippery slope skier
 
Costa P's Avatar
 
Join Date: Sep 2010
Location: South Africa
Posts: 179
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DIY tool for external oil thermostat cap

I eventually succeeded to remove the small cap (oil pressure relief).

This was my 3rd attempt after 2 previously failed attempts....more about those here:
930 rebuild – The revival of my mothballed project

I figured it may help someone else to know what worked for me, so here goes:

The mild steel “coin” was from the failed attempts. It twisted without handling much torque. I hacked the high strength steel version out of a chisel! It went into the slot nice and snug with the aid of a hammer.








The high strength steel version got the job done like a breeze. I used a 600mm long power bar with a 21mm socket over the hex of the chisel.
Surprisingly, the tip did twist and deform!
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Costa P
'85 930 Grand Prix White ...the oil leak rebuild which mutated into MoTeC EFI+twinscroll GT35R+twinplug+ ...

930 rebuild – The revival of my mothballed project
Old 10-17-2018, 02:26 PM
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Slippery slope skier
 
Costa P's Avatar
 
Join Date: Sep 2010
Location: South Africa
Posts: 179
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Removal of large cap (thermostat)

930 rebuild – The revival of my mothballed project

I used a friction spanner to loosen the 50mm cap
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Costa P
'85 930 Grand Prix White ...the oil leak rebuild which mutated into MoTeC EFI+twinscroll GT35R+twinplug+ ...

930 rebuild – The revival of my mothballed project
Old 10-17-2018, 02:37 PM
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75 911s's Avatar
 
Join Date: Aug 2015
Location: Las Vegas
Posts: 1,785
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Nice! love the custom tool. There's a pretty cool replacement cap that a member makes that has a hex pattern built into it, not that you need it now. :-) I think on mine I soaked overnight with pblaster and then used cut a piece of thick aluminum as a key. Mine was obviously not as "on there" as yours though.
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Duane

http://forums.pelicanparts.com/porsche-911-technical-forum/878569-born-75-me-my-new-911s.html
Old 10-17-2018, 02:43 PM
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Cr@pcan Rescuer
 
2jmotorsports's Avatar
 
Join Date: May 2010
Location: Orange County
Posts: 485
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What a timely DIY. Im about to do this myself.

Also, for your hardlines, I was able to remove mine with no drama soaking with PB Blaster once a day for a few days then hitting each fitting with a propane torch. After about 2-3 heat cycles and the use of these wrenches:

https://www.harborfreight.com/15-piece-metric-service-wrench-set-93668.html

All 4 hardlines came off with no issue.
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Jose - 1983 911SC Coupe
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Old 10-17-2018, 03:40 PM
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Join Date: Jul 2006
Location: San Diego, CA
Posts: 92
I made these up to simplify the remote thermostat plug removal process.


I also make plugs with hex heads for easier removal.
FS: Remote Oil Thermostat Press Relief Cap, 916.107.276.00 (Small), $21.38

FS: 911 Remote Oil Cooler Thermostat Cap, 911.107.155.00 (Large), $25.62
Old 10-19-2018, 08:57 AM
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Slippery slope skier
 
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Join Date: Sep 2010
Location: South Africa
Posts: 179
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Auxiliary Oil Thermostat Hex Caps
JummyT, those tools look awesome and the hex caps look even more impressive 👍🏻👍🏻
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Costa P
'85 930 Grand Prix White ...the oil leak rebuild which mutated into MoTeC EFI+twinscroll GT35R+twinplug+ ...

930 rebuild – The revival of my mothballed project
Old 10-19-2018, 12:02 PM
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