Installing SSI heat exchangers on 3.2 - what to expect

[vansicklenmi]

Thanks, and very sano!

But I want to make the hole go away and that will require replacing the entire rear tin piece. I just don't know which one to purchase.

[Discseven]

Originally Posted by jjeffries

Karl are you doing all this work under the veil of darkness in order to keep the HOA at bay? Motor looks superb.

Best as always, John

"Veil of darkness." That's poetically you John! Appreciate the comp

Rebuild has been a drama novel of considerable length. Many chapters have been unruly---just the torture I (we) like. All chapters have so far ended well. Wrap up pends. In a nutshell, I had a trade arrangement with a Porsche friend of mine where he was to do the rebuild (in his shop.) I took the build over given his blistering snail's pace. Getting workspace in my condo was a fluke... On a wild hair, and after failing at finding suitable workspace elsewhere nearby, I discussed the problem in hand with my building's Manager. This is a guy with whom, years ago, we could have been handed dueling pistols and gladly took aim at each other at close range. Things have changed. For the much better. Workspace in the condo was had. Although it was swiss-cheese in apparent security, it was a great space to work in once I got over my initial cheesy-concerns. Agreement that made the build condo-possible was to keep a tight lid on it. That was---very fortunately---deftly managed by the very few who knew what was happening. Only security staff and a few maintenance people knew. Were it otherwise, and had news of this engine stuff reached the wrong people at the right time in the condo, It would have been an HOA chit-storm. Manager took a considerable risk for me. Come to think of it, he & wife are due a fine dinner.

Condo workspace & engine pics are here... https://forums.pelicanparts.com/porsche-911-technical-forum/1134500-need-help-finding-space-rebuild-miami.html
.

[jclporsche]

Not many good posts on SSI install issues, so I'll resurrect this one if you all don't mind. I got a great deal on a pair of slightly shipping dented (otherwise brand new) SSIs from Jeff Alton up at Turn3 Autosport Inc. He also gave me a good deal on a new Dansk 2 in 1 out muffler, with all required gaskets. I checked around about installation help, low of $400 to a high of $2500, not saying from who. As I'm retired, and having lots of experience working on my 911s over the last 30 years, I decided to dive in on my own.

First major discovery was the heater air inputs pointing to the outboard on each side. I didn't want to reroute the air tubes in my engine compartment, want it to remain stock as possible (1988 3.2). One youtube i watched featured a set of SSIs from Dansk that look to fit directly without changing the air from engine fan. Unfortunately, I now already own a pair, so not going to buy a different set. I decided I will try to match the way those route the heater air. Still working on it, will update as work proceeds.


First pic = new slightly dented SSIs


second pic = the Dansk system I'm going to try to match, some cutting and brazing will be required.

[fallingat120mph]

Originally Posted by jclporsche

Not many good posts on SSI install issues, so I'll resurrect this one if you all don't mind. I got a great deal on a pair of slightly shipping dented (otherwise brand new) SSIs from Jeff Alton up at Turn3 Autosport Inc. He also gave me a good deal on a new Dansk 2 in 1 out muffler, with all required gaskets. I checked around about installation help, low of $400 to a high of $2500, not saying from who. As I'm retired, and having lots of experience working on my 911s over the last 30 years, I decided to dive in on my own.

First major discovery was the heater air inputs pointing to the outboard on each side. I didn't want to reroute the air tubes in my engine compartment, want it to remain stock as possible (1988 3.2). One youtube i watched featured a set of SSIs from Dansk that look to fit directly without changing the air from engine fan. Unfortunately, I now already own a pair, so not going to buy a different set. I decided I will try to match the way those route the heater air. Still working on it, will update as work proceeds.


First pic = new slightly dented SSIs


second pic = the Dansk system I'm going to try to match, some cutting and brazing will be required.

Look forward to updates. I am about to purchase the set you included to keep stock air, but will appreciate your install and "take" on things. 86, coupe here...

Timely resurrection...as I have been looking down the rabbit hole myself - good luck with your project.

Erik

[jclporsche]

Hi Erik,
I decided not to operate on the SSIs. Now I'm getting some silicone 60mm ID parts to route the air. Will post pics after I get them in.
This is a good article to read first: https://www.pelicanparts.com/techarticles/911_1974_heat_xchangers/911_1974_heat_xchangers.htm#Customer_Comments_Book mark

Some issues I had:
Detaching the oil lines from the aluminum oil thermostat in the rear passenger side wheel well was very difficult. My car is fairly all original, and though well kept (garaged and minimal bad weather driving) it is 37 years old. I doubt these oil lines have ever been removed since it was put together in Germany. I used a lot of penetrating lube over several days, also tried a propane torch on the nuts. But finally they just broke loose using a 18" breaker bar.
The other end of the oil line at the engine case on driver side is hard to get a wrench on also. There is a hex head plug right next to it and an oil tube on the other side of it. The crows foot wrench I bought for these lines is bulky, I had to grind part of it away for some clearance. Removing the hex plug helps, but be careful, it's got a spring under it and wants to pop out at the last turn.
My exhaust stud nuts came off fairly easy. We just rebuilt the engine 20k miles ago, and had used good never seize. But it is a pain to get a wrench on them. Even worse at reassembly. The SSIs are even more obstructive than the original HEs. Helps if you have smaller hands, or use a magnet maybe.
The new SSI heater outlet tubes are longer than the originals. On my car only about 1/2" between them and the heater control boxes in front of engine compartment. Some say to cut a bit off the heat control boxes under the car. I decided to shorten the SSI heat outlet tubes about 3/4". much easier done on the bench than under the car. had to flatten the seam on the sides to give more room for the flex hose to fit.
In my case, the Dansk muffler interfered at the fan belt cover when I tried to bolt it onto the new SSIs. So I made two 1/2" thick spacers and got two more gaskets to move the new muffler back a bit.
It's looking good to refill oil and start up (less the heat for now, waiting for parts. Will post more once that's complete.)