Porsche 996 Suspension Overhaul

[Van B.]

So, a little backstory is probably warranted before I get into this.

I bought my 996 about 9yrs ago and have been steadily changing it into my own vision of the perfect 911. Unlike many, I’ve always loved the 996. I never understood the mocking attitude or arrogance that so many “Porsche enthusiasts “ show whenever the company makes something that is a change in design. That said, I’m a gear head, and the fact that the 991/992 won’t even permit the owner to admire the engine has me rolling my eyes lol. For Porsche to boast about how 70% of all 911’s ever produced are still on the road today. They seem to have shot themselves in the foot by preventing enthusiasts from working on their cars. So, my reasoning is that the 996/997 are the end of the era for a true gear head 911... But I digress.

Back to the topic at hand. Recently, I have drastically changed the chassis on my car. I have gone with a full Ohlins setup, GT3 sway bars front and rear, and replaced every rubber bushing with monoball components. The only exception was the suspension top mounts and subframe mounts. Those are still rubber. But, I filled the top mounts with 3M urethane in order to stiffen them up. I also added caster pucks from Elephant Racing (ER) in order to dial in caster left to right.

I’m not here to brag about how cool my car is, even though it’s pretty sweet. Rather, I want to post a record of what monoball suspension is like on the road. I found almost no information when I was trying to make this decision and the lack of info caused me to waffle on this course of action more than once. So many people have asked, got the standard forum parrot response, and ended up going with urethane.

So, what is my experience? Bottom line, IT’S UNREAL!!!!! I’m re-learning to drive the car. I can actually feel the gear backlash in the steering rack now lol…. It’s always been there, but you would never know with rubber bushings and all the deflection/slack that must be taken up on turn-in.

Noise: Yes. Even with rubber top mounts and subframe bushings, you will hear grainy pavement in the cabin. For those of you that have done engine mounts to the semi-solid variant, it’s exactly the same change. So, for me I can feel the engine tickle my butt under certain loads or RPMs, and I can also feel when I transition to different grades of pavement. But for me, it’s fantastic. It adds so much more to a backroad drive. And with the windows down, you can’t hear anything but the wind and the engine, but I still have that literal seat of the pants feeling to tell me what’s going on.

Response: Laterally stability is noticeably different. The only thing moving under cornering loads are the tires and shocks now. So, there is much less sawing of the wheel. Also, turn in is dramatically changed. To the point that if you have a familiar route, you will need to treat it as a new route before you get back up to speed. Driving over the inside apex is a real threat until you reprogram your brain!

If folks here would like to know more or see some things, I’ll be happy to build on this post. If not, that’s fine too, the search bots will find this and maybe the next dumb SOB with the same idea as me can find some info that will push them along in their project.

Van

[Van B.]

[keitho64]

The car looks fantastic and I completely agree with your statement of the 996/997 marking the end of an era for a car that can be tuned by the owner.

I recently purchased a 996 after having a 69 for 17 years. I sold the 69 about 3 years ago and when I started looking at 996's I fell victim again. The 996 is still relatively light, narrow and a flat out riot to drive.

I for one would like to see more about your build up. It sounds like you really have it dialed in for your goals, which what this is all about. I'd enjoy reading what you have to share.

What exhaust do you have on it?

[Van B.]

Keith, thanks man, I appreciate that! The exhaust is a bit of a custom job. And could probably have it’s own thread lol. The headers are a salvage job that I rebuilt. The mid-pipes are test pipes that I welded flowmaster 200cell high flow cats into, $70 each! And the mufflers are a Craigslist find that I did some customization on. They are Mille Miglia with custom mesh tips. Gives a bit more laminated flow to the exhaust and changes the sound a bit…. Sounds like two triumphs racing each other lol! Oh and everything is ceramic coated by Jet Hot.

[Van B.]

[keitho64]

That is impressive! Nicely done. Do you have any issues with drone at certain RPM?

[Van B.]

Originally Posted by keitho64

That is impressive! Nicely done. Do you have any issues with drone at certain RPM?

Haven’t really done any cruising in this car with the exhaust on it. Usually, the wife and I jump in to go for an adventure in the morning or evening. And I see if I can scare her at least one per drive lol.
But, there is a load+RPM combo that can make some reverb. But, it’s a combo that tells me I’m in the wrong gear. So, something like 2k-ish RPM and half throttle maybe?
Overall, it’s not a loud exhaust but it flows real well and makes beautiful music!