@#%& you used heat exchangers!

[allaircooled]

I can't seem to catch a break lately. After taking a torch and bending my new hard oil line to get it to fit I am having trouble with the heat exchangers. I bought them from someone on here a couple years ago but just now getting to the point where I can install them.

First problem is the hole you would use to tighten the barrel nuts don't line up with the nuts. I bought the long hex head tool from Pelican for this but there is no way I can use it. I managed to get one side with a cut 8mm allen key and a 8mm 1/4" drive socket. The other side is much worse. Then I thought, will my new M&K muffler even fit. Of course not!! the distance between the flanges is about 1.5" closer together than on the muffler.

Not sure what the deal is. Maybe I should have just bought the SSI exchangers from the get go. Rant over.

[zippy_gg]

Ouch! It seems to me that you have bought exchangers for the wrong model year/engine size.
See if you can sell those and buy the correct ones for your car.

[allaircooled]

Sorry for the rant. I am going through a divorce, 1st quarter is always slow for work, and I haven't driven a Porsche in 5 years. haha I figured out the muffler. It actually wasn't a big deal. Just used a ratchet strap.

As for the holes in the exchanger. They don't line up with the bolt holes on the flanges where it would mount to the heads. So it wouldn't matter what engine they were for, they still won't line up. Maybe after years of heat cycling?? I will just have to come up with a way to get to the barrel nuts.

[eastbay]

Just use the 12mm copper coated nuts instead, then you can end wrench them. Barrel nuts on the exhaust show another glaring Porsche engineering shortcoming.

I think Pelican sells them as Mercedes exhaust parts.

here you go:
Exhaust Nut, (Split Collar) - 8 X 1.25 mm (12 mm Hex) Part #: 000-990-32-50-M36

BTW, bolt the whole system together loosely, so it wiggle aligns easily, then snug the nut and bolts

[911pcars]

Originally Posted by allaircooled

Sorry for the rant. I am going through a divorce, 1st quarter is always slow for work, and I haven't driven a Porsche in 5 years. haha I figured out the muffler. It actually wasn't a big deal. Just used a ratchet strap.

As for the holes in the exchanger. They don't line up with the bolt holes on the flanges where it would mount to the heads. So it wouldn't matter what engine they were for, they still won't line up. Maybe after years of heat cycling?? I will just have to come up with a way to get to the barrel nuts.

Source some M8 nuts made of copper/copper-plate (for increased corrosion protection) with a 12mm hex head (instead of 13mm). The reduced hex should make it easier to access the heat exchanger-to-head nuts. Search the archives for tools that work best to R&R heat exchanger nuts.

1-1/2" is a lot of real estate to place in tension. There's a potential for metal fatigue sometime down the line. Discuss with a skilled muffler shop if they can reduce the stress with some strategically-placed torch heat in the system. BTW, the side-to-side heat exchanger/exh. header spacing and/or factory-spec muffler inlets are the same for all air cooled sixes save for any minor machining to the case halves and heads. Perhaps a PO had performed a mod at some point.

Sherwood

[allaircooled]

Originally Posted by 911pcars

Source some M8 nuts made of copper/copper-plate (for increased corrosion protection) with a 12mm hex head (instead of 13mm). The reduced hex should make it easier to access the heat exchanger-to-head nuts. Search the archives for tools that work best to R&R heat exchanger nuts.

1-1/2" is a lot of real estate to place in tension. There's a potential for metal fatigue sometime down the line. Discuss with a skilled muffler shop if they can reduce the stress with some strategically-placed torch heat in the system. BTW, the side-to-side heat exchanger/exh. header spacing and/or factory-spec muffler inlets are the same for all air cooled sixes save for any minor machining to the case halves and heads. Perhaps a PO had performed a mod at some point.

Sherwood

Actually after I cooled down a bit the spacing was no where near what I originally thought. I was just aggravated all ready and needed to get out of the garage for a little bit. The other six nuts are 12mm copper nuts. I did manage to get the barrel nuts on with a allen key that I cut and an 8 mm ratchet wrench. I might just order some more 12 mm copper nuts and replace them while the engine is still out. I can imagine it being a nightmare to remove years down the road.

Thanks for all the advice and again, sorry for blowing off steam here. It actually kind of helped.

[JJ 911SC]

Originally Posted by allaircooled

... I might just order some more 12 mm copper nuts and replace them while the engine is still out...

Along with a box wrench and "Bob is your uncle"...

For those not familiar with that expression, let me google that for you https://en.wikipedia.org/wiki/Bob%27s_your_uncle

[zippy_gg]

Originally Posted by JJ 911SC

Along with a box wrench and "Bob is your uncle"...

For those not familiar with that expression, let me google that for you [url]https://en.wikipedia.org/wiki/Bob%27s_your_uncle

I heard a different definition for BOB from a lady friend: Battery Operated Boyfriend. Yup, she was going through a long divorce and she was not pretty...
Urban Dictionary: battery operated boyfriend (bob))

[JJ 911SC]

Originally Posted by zippy_gg

I heard a different definition for BOB from a lady friend: Battery Operated Boyfriend. Yup, she was going through a long divorce and she was not pretty...
Urban Dictionary: battery operated boyfriend (bob))

Gilles,

Did you run this post by Mme Blancheville or should I