Project 996.. Here we go again..

[rattlsnak]

Began my quest to find another project 911 a few months ago. Was aiming for an SC or 3.2 and wanted to keep it simple (no lime green paint this time!) and build a well setup fun toy. Nothing extravagant, just add stiff suspension, RS interior/sport seats and leave the motor stock. After looking at a few I ran across an '03 996 that was in the process of getting stripped after a major engine failure. I have had many 911s of all years and even 2 993s, but have never crossed over into 'no mans land' (water cooled 911s) so i figured what the heck, its time. Made an offer and had it delivered a few days later.







I immediately started the research and went to work on it......

[rattlsnak]

Sourced the bumpers/hood/headlights/tailights and many brackets/clips/air ducts etc. that were missing and got everything all repaired and painted.

[rattlsnak]

Next up was the drivetrain. I sourced a newly rebuilt 3.6 with the new IMSB retrofit kit from Texas and then installed new clutch/PP/TOB and did what is called the PSE hack to the exhaust (also called Gundo or Fister hack) which simply puts a small bypass pipe in line. It is quiet as stock until you step on the gas and then it gives out a very nice rumble.

[rattlsnak]

Next up was the install..





Adding 6 gallons of coolant with no air bubbles took @ 45 seconds with the UV Airlift tool!

[rattlsnak]

Installed a 997 GT3 short shifter and Bilstein Sport struts with Eibach sport springs and strut brace bar...





Picked up some Speedlines, headed to the alignment shop..

[rattlsnak]

and here she is today:

[WPOZZZ]

Looks good! What did you do with the Kinesis wheels from the early pics? You can also source a turbo front bumper for your car to give it a sportier look.

[Flojo]

You make it look just to easy.
Well done!

[christiandk]

Great job!

How is the quality of the engine casing and other components compared to the aircooleds?

Is it as easy to work on? My own guess is NO.

[Elombard]

Looks great = perfect stance. Does it still have AC and a radio? If so you know you are getting old!

Lime Green Paint for the Win!

Great project! Good to see 996's brought being back to life.

[Shuie]

Nice work. It's motivating to click on a thread like this and see a car that is in pieces go back together again. It looks like it was done in a weekend. Good job finishing the project and getting another one back on the road!

[1990C4S]

Nice job.

[weseeeee]

Looks great, and I agree, you make it look so easy! Enjoy!

[PCA7GGR]

One of our local shops does the same mod on the mufflers.

[88911coupe]

Maybe you mentioned this but did you do any of the Jake Raby/LN Engineering upgrades to avoid another catastrophic engine failure?

[BRPORSCHE]

Awesome Marc!

[wayner]

This just hit me as early prices rise and your project popped up.

As the owner of a long hood, I am now feeling the way that I imagined an old timer with a 356 must have felt when people like me started restoring 911s.

...the passing of one era and the start of another.

[KNS]

Very cool..!

Impressions..?

[rattlsnak]

Originally Posted by WPOZZZ

Looks good! What did you do with the Kinesis wheels from the early pics? You can also source a turbo front bumper for your car to give it a sportier look.

I thought about going with a turbo or aero front bumper, but we had one at the shop already so free wins! I still have the Kinesis wheels but havent decided whether to keep them for sticky tires, or sell them yet.

Originally Posted by christiandk

Great job!

How is the quality of the engine casing and other components compared to the aircooleds?

Is it as easy to work on? My own guess is NO.

Well, these engines do have their issues that's for sure. Everything from RMS to IMS and cracking cylinders, etc. But overall, the rest of the car is actually much easier to work on than previous models so far. Everything seems to be modular and easily accessible. An example would be the front or rear bumper. The whole complete piece comes off in less than 5 minutes. Try that with a pre- 89 model!

Originally Posted by Elombard

Looks great = perfect stance. Does it still have AC and a radio? If so you know you are getting old!

Lime Green Paint for the Win!

Yes, it actually has a double din nav/sirius/bluetooth/hands free $2000 stereo from the previous owner! And the AC blow COLD!

Originally Posted by 88911coupe

Maybe you mentioned this but did you do any of the Jake Raby/LN Engineering upgrades to avoid another catastrophic engine failure?

Yes, it has the IMSB retrofit bearing by LN installed.

Originally Posted by KNS

Very cool..!

Impressions..?

I have driven a few 996s around the block and such before, but this is the first time I have driven one in an everyday capacity. Although it is definitely bigger and heavier than earlier cars there is no doubt it is still a 911. It doesnt have that 'raw' feeling that everyone describes when talking pre 89 models, but the power is amazing and it handles great, shifts great and sounds great!


And for those wondering about the IMS bearing, below is a picture of the intermediate shaft with the bearing still installed. That bearing goes bad and gets loose so the shaft assembly moves around eventually causing the engine to jump timing with a catastrophic result.