SSI Installation

JSZ · 05:34 AM

After a great deal of reading and planning, i thought my SSI installation would have gone smoothly.
I recently purchased a pair of thick flange, SSI that were new old stock. I was reassured they were correct for a stock 82 SC. I went through the oil line install no real issues I could not tackle. However when I went to install the SSI's they would only go up about flush with the studs and the flanges. So I took some measurements, my port sizes are 38.60mm, the belled portion of the SSI's above the flange averaged about 39.50mm.
I believe the two SSI part numbers are 484122 and 434646
So I have a few ideas, shrink the tubing or other thoughts?
Thank you for your assistance.

Flat6pac · 02-21-2019, 04:52 AM

Those heatboxes are specific for Carrera.
The inserts on 3.2 are larger than the 3.0.
Usually the SC pipes are used on Carrera and no one would notice an improper fit.
Bruce

75 911s · 75 911s's Garage

Yep. They make two "thick flange" SSI. I have the other style without the insert on my 75.

You need the other style as well, although desperate people have cut the inserts off (bad idea imho.)

JSZ · 02-21-2019, 05:31 AM

Have not considered cutting the inserts off. Thinking I can swage these with a die Or possibly 1 or 2 vertical cuts in the insert to allow for the excess material take up, then tig close.
Well all good intentions don’t always work with out more thoughts and efforts.
Thanks much.

G450X · G450X's Garage

I installed a new set for my ‘82 3.0 a few years ago before SSI was sold to Dansk. I had the pleasure of speaking to John a few times, and he was rightfully proud of his product.

I was absolutely amazed at how well they fit, the the little port inserts were absolutely spot on.

I know it would would be a hassle to try and swap them out, but please try before you hack off the insert sections. They are metal works of art from a small California business that no longer exists...

QueWhy · 02-21-2019, 01:18 PM

Don’t cut them off, they are correct for an 82 SC US spec.

I also have an 82 SC and installed the SSIs with inserts like you have pictured. They didn’t want to fit at first but I used a brass brush on a dremel to clean out the ports on the heads a little and they fit fine after that. Just make sure you rotate the crank to close the exhaust valve for the cylinder you are working on.

davidpsalt · davidpsalt's Garage

Just an FYI - if you run into issues and would rather get out of them and buy another set for your SC, I have a Carerra 3.2 and would be willing to buy the set you have from you. Feel free to PM me - if not, keep us posted on your install with pics and feedback on how you like them. I am considering taking the same route but need to research the changes to oil line and heater pipes ... regardless, I definitely want to do this as well as the Steve Wong chip.

JSZ · 03-18-2019, 05:18 PM

I finally have had some time to complete the rework of the SSI's for install on my 82 SC. I had my son machine a die that was drawn down on to the insert and swaged it from 39.4mm to 38.43mm. Absolutely worked perfect and fit right up. The biggest issue was there were only two access holes and not the three through the heat exchanger for the barrel nuts. So I installed a copper nut in lieu of the barrel at the missing access hole.
So if someone has this issue in the future I have the tooling to allow for the fitment to an SC
Photo 1 is the die, two and three shows the inserts after swaging

LIRS6 · LIRS6's Garage

Nicely done Jeff!

Jason

trond · trond's Garage

nice fix ! I got a used set of SSIs without those insert sleeves and has been running that for about 10 years now without any issues (leaks)

JSZ · 03-19-2019, 05:12 PM

Completed the SSI installation, long road, however satisfied with the results.

JSZ · 03-20-2019, 05:08 AM

Here are a few photos of the die in use for the sawging process. It is a two step process with a taper drawn on first and then the die is flipped over and drawn down with the straight side to achieve the shrinking of the insert.

jjeffries · jjeffries's Garage

Thoughtful and instructive. Thanks. John

sigchuck · 02-13-2021, 02:05 PM

Jeff, were your SC heads previously ported? I'm in a similar predicament, but don't have my heads off to measure the actual size of the port. The Bruce Anderson book indicates they're 35mm though. Does anyone know for sure? Is the 35mm measurement just the diameter at the combustion chamber and it tapers out as it gets to the mating surface?

Thanks for your help!

$yncro · 04:04 PM

I have an 80 with 35mm exhaust port. Installed a
Used thick flange SSI's from 3.2 and it fits no problem.
Didn't have any issues at all. Got lucky maybe.

JSZ · 02-13-2021, 06:30 PM

Quote:

Originally Posted by sigchuck

Jeff, were your SC heads previously ported? I'm in a similar predicament, but don't have my heads off to measure the actual size of the port. The Bruce Anderson book indicates they're 35mm though. Does anyone know for sure? Is the 35mm measurement just the diameter at the combustion chamber and it tapers out as it gets to the mating surface?

Thanks for your help!

Hello, I believe they were not and the engine original and never broken down, until I got it. I can't answer your question on the port size, will try to find my notes.
Jeff