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best purchasing experience i have had
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For me it was the best purchasing experience I have had for anything in the past.
Flat 6 Innovations Motor discussion and review ( for past and interested buyers )
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Leading evidence: 'best purchasing experience i have had' (1 discussions report identifying this cause; no attributable repair resolution). Across 1 matching discussions, the most frequently mentioned possible cause is 'best purchasing experience i have had' (1 discussions; 1 report identifying it and 0 suggest it). The most frequently discussed action is 'Check book' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
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I used the FSI shop and installed the engine in the car, then we began the startup and break in process.
Flat 6 Innovations Motor discussion and review ( for past and interested buyers )
Install gutter guards
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I’ve installed gutter guards, so no more cleaning out the gutters.
Flat 6 Innovations Motor discussion and review ( for past and interested buyers )
Install on budget
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Stage 2 4.0 Track Performer was installed on budget and on time in Spring/2016.
Flat 6 Innovations Motor discussion and review ( for past and interested buyers )
Install reasons i won't go into
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It subsequently got a brand new FSI 4.0 stage II engine installed for reasons I won't go into but Jake and LN will always have my total respect & admiration, as well as any business I can give them.
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Install reasons i won't go into
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It subsequently got a brand new FSI 4.0 stage II engine installed for reasons I won't go into but Jake and LN will always have my total respect & admiration, as well as any business I can give them.
Flat 6 Innovations Motor discussion and review ( for past and interested buyers )
same price as was paid new
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Porsche sells you the new car, sells replacement parts over 20 years, and then restores the car again for probably the same price as was paid new, and then sells you replacement parts again over the next 20 years.
Flat 6 Innovations Motor discussion and review ( for past and interested buyers )
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Over the past Winter I had my 996 3.6 L motor built by flat 6 innovations into a 4.0 L Stage 2 Track Performer. Because I had such a great experience with them, I figured I would start a thread to see if I could get some other FSI owners to chime in one their experience and what motor they had built with FSI. I never see a much for customers on RL talking about their motors and the experience with FSI. Lots of people on these forums question what FSI does and the value of the investment. Here is an opportunity to share your experience and what you think of their program and motors. For me it was the best purchasing experience I have had for anything in the past. Their customer service was exceptional, and communication was unparalleled. I must have been a pain of a customer with all my questions and comments into their ticketing system however they always answered me in kind and never gave me the impression I was bothering anyone. Great company in my opinion. The motor they built, amazing. It has a big mid-range torque push with a nice peak power ban as well. Is there anyone who is willing to share their experiences? If so, please do so here! I would love to hear from some R motor owners. If I get some interest, I will share more on my experience and answer any questions anyone has on their program.
My experience with FSI and ongoing relationship has been excellent. When my engine went South, I spent time researching various options. After speaking with Jake for 10 minutes, I knew I had found my engine builder. Stage 2 4.0 Track Performer was installed on budget and on time in Spring/2016. I enjoy his direct approach with no BS. I attended a Raby engine rebuild class and it was a fun experience sharing time with other car nuts. Jake and his entire team made us all feel welcome at his place. The car has rolled about 10K track miles since the rebuild, and is headed to Eagles Canyon Raceway this weekend. I highly value my continued relationship with FSI and my friends Jake & Jud.
Awesome, thanks for posting! It looks like you are using your motor the right way! I agree Jud and Jake are great guys. I love Jakes no BS attitude. That is why I made this thread, I want to hear from more customers like yourself with some experiences to share.
Attached is the link from my thread posted in 2019. It addresses many of your questions/requests for this thread,
https://rennlist.com/forums/996-foru...uild-info.html
Thank you for sharing! Searching on RL is strange to say the least, never found your thread before. I will check it out. Motor still running strong? How many miles do you have on the motor now?
Public disclaimer: I work PT at FSI as test/break in driver . I am a " twofer " customer of FSI . In 2015 I started a conversation with Jake about a 2002 Boxster S he had purchased with intermix . That conversation turned into us making a deal for it . Part of the deal was Jake building a 3.6 for it . Approximately in the middle of the build I was diagnosed with prostate cancer ☹️
Called Jake and he agreed to put a hold on the build until I got past the situation . No fuss no muss . Happy to say I kicked that cancer to the curb and the build was completed in December of 2015 . The build was documented on the 986 forum . Engine put down 282 wheel HP and she is a joy to drive . Zero issues and I still drive her today .
The Boxster was to be my last hoorah as I retired 5 years ago . Then the PT job popped up with FSI . Last December I bought a 1999 996 C4 with an engine that had spun a crank bearing . The plan was to build a 3.8 Stage II which we did .
Four weeks ago we put her on the Dyno and put down 318.55 HP and 290 lb ft of torque at the wheels . She pulls like a freight train 😊. To say that I am a happy customer is an understatement . Both engines are smooth with very tractable torque curves . Maximum HP was never the goal , solid reliable daily driver quality was the goal . On my two builds the team easily over achieved .
I have driven over 150 customer cars in my time working with Jake/Jud . I am always impressed with the care and quality that goes into every build . Failure is simply not an option . The work and $$$ that goes on behind the scene is amazing . Lots of inventory purchased to support the business/customers that many shops just can't do .
Every engine builder Jake employs is 100 % committed to building the best engine they can . No short cuts , no excuses and no BS . That is a recipe for success and is a repeatable process . Are there other good engine builders out there ? Yep . As good as FSI ? Maybe. But I know where I wanted to spend my dollars .
Final thoughts and sorry for the long fan boy response. The relationship between FSI/LN Engineering and Len Haufman is amazing to watch and be part of . Each highly dedicated to their piece of the puzzle to make it all work . My time at FSI comes to an end next year as they transition to a new business model . It has been an honor and privilege to have been a tiny piece of this successful puzzle 😁
Thanks for chiming in! It is very cool to hear from someone who works with FSI! If they were close to me I would be begging Jake to hire me, I would love to get a chance to work with those guys. Your job sounds like a blast, too bad its coming to an end. I wonder if you drove mine?? Mine was at FSI from late October to late January. Black 2005 996 with a GT2 rear wing. The white one is my friends 991.1 GT3 who I keep up with in the FSI powered 996.
You have 2 of their motors?? I am jealous!
@996C438
Hopefully you got to test drive what's now my 997.2 4s 4.0 Stage II when FSI completed it. "pulls like a freight train" is an understatement, it's really hard to describe the lengthy torque band until you've experienced it. What a great PT job to have!
I have been driving cars for FSI since 2017 , basically driven them all since then . We have a 52 mile mountain loop that I call the " Raby ring " that I drive each car at least twice on sometimes more . I have no favorites I enjoy each car for what it is .
No tears to be shed for my job coming to an end . It is an evolution of the business and I have been made fully aware . I turn 65 in January so it's all working out great for all involved .
My 996.2 is currently at F6I being built into a Stage II 4.0 with all the options.
I can't wait to get it back.
The wait from contract signing(January 2021) to shipping to GA(July 2022) was not too bad because I was still able to drive and enjoy my 996..
But the wait, and the empty garage space since shipping, has been rough.
Many times I think about going for a drive, or washing my 996 and then...it's not home to enjoy.
I'm ready for some 996 seat time...I just have to wait a little longer.
Most of the regular members here on RL know of my affiliation with the Knowledge Gruppe and Flat 6 Innovations. I've been both a customer and collaborator with Jake Raby for more than 4 years. Even if we didn't collaborate on educational projects for Rennvision and the Knowledge Gruppe, my thoughts about this man and his team would not have changed. I know this may seem like a lot of back patting, but there is no one that knows these engines like Raby. He repaired my M97 engine when a top Porsche shop in Texas thought it was a lost cause. Jud Fink had the car shipped to Flat 6 Innovations in Cleveland Georgia and I was prepared for the worst which would mean getting in line for a rebuild or purchasing a "Stocker" engine. At the time, they had a few in stock. Got an exciting phone call. Raby and his team was able to save the engine. The car basically suffered severe AOS failure which was misdiagnosed by the shop in Texas. Flat 6 could have easily done what the other shop wanted to do (i.e. engine rebuild or replacement), but instead they did the right thing and was able to repair the damage. A deep breath of relief and the car has run flawless ever since. That was 2 years ago.
I've been working with Mr. Raby directly since he decided to merge with LN back in January. The things I have learned in this amount of time are unreal. The guy has everything memorized, so I am happy to see him finishing the M9X Performance Book that he's been working on for years.
I've had my feelings hurt a few times while learning, but after I realized that the way he teaches is by pushing people to only give their best effort I was able to set my feelings aside. Since then he has taught me even more.
Since January I have been answering technical tickets and having phone chats with FSI engine owners that have sometimes had their engine for well over a decade. In my prior job (elsewhere in the Porsche world- not LN) I did a similar task and every other customer I talked to was pissed off, or calling to complain. At FSI I have never heard a single complaint, and never dealt with an irate purchaser. I have never even heard of one.
The FSI purchasers are a different group, they don't get into social media or forums. I moderate the FSI Facebook Lounge which is a private group with only 80 members, which is a small percentage of the over 3,000 engine purchasers they have on the books. If you are an FSI original engine purchaser and want to interact with others- join that group. I don't think you'll find many posters on these groups with FSI engines. Lots of them read forums, but they don't want to deal with the issues of posting. This is based on what they have told me directly. Even there we seldom see posts in the group. Lots of the purchasers are at an age where they don't care about nonsense, or bragging. They want a car that works, has power everywhere and is fun. Jake asks them many questions during the Gauntlet period, and I've seen applications get turned down if someone fits a description that he doesn't believe the program will adequately accommodate. If they say the wrong things, he won't even think about adding their application to the pile. In the beginning I didn't understand why this was, because my thinking was if someone had the money and wanted the engine just sell it to them. After these months have passed I see now that to him less sales is more. Why? Well there's way more demand for the FSI level of engine creation than they can ever meet, so he feels that selling the engine to the wrong person is worse than not selling an engine in the first place. That is especially true moving on, since FSI will reduce engine sales by more than 50% and have a lot more fun doing each job than before.
All the changes at FSI are based around how the engines are orders, and sold. This will be very good for everyone. I am glad to see that Mr. Raby is able to get back to only doing what he loves, and not dealing with the business anymore. He always thinks outside the box and he explained to me that dealing with business and people is about as close to Hell on Earth as he could imagine.
Glad to see the positive reviews here, some of you guys will be dealing with me in the future, especially if you want to add any other newly developed Raby components to your existing engine.
Well said! I also do not do any social media at all, I poke into rennlist here and there. I created this thread as half of what I see on RL is people questioning FSI's program. I wanted to give some happy owners a chance to discuss their experiences. Thanks for sharing the FB group, I deleted my FB account a couple years ago as I have no interest in peoples manifested fake lives. However I may set one up just to go to the FB group. I am happy I got my FSI motor when i did and did not hesitate. I still want to have Jake build me a R40 motor someday though....
Back in Jan 2009, I came upon a site http//www.flat6innovations.com/engine-failure-illustrated. After reading what was presented at the site, I downloaded all of the information from broken cranks, timing chain failures with only 30k miles, D chunk failures, unseen cylinder failures from the casting plants, engine failures from lightweight flywheels, and the use of powdered metal for their rods and cranks all of which were illustrated with photographs. Nobody in the entire world of Porsche at that time had attempted to write and document the entire modes of failures. What I came away with for future references ( fourteen pages worth ) was that Jake took full heat to document all of these maladies with pictures and comments to explain in great detail what was happening. What was chillingly absent from all of the media at that time was the intrinsic curiosity from so-called experts and motor journalists who never questioned nor wrote about these issues in great detail that affected owners who purchased these cars at nosebleed prices. Jake, over the years, has never appeared to be another marketing maven trying to create demand so he can force his goods to the Porsche marks but voiced a big concern that the factory knew about these issues. History is still open to what constitutes the greatest dangers, a sclerotic manufacturer or having a voice and ability to fix these problems and then back them up. If anything, we are all indebted to Flat 6 and Jake for his products, knowledge, guidance, and curiosity, as we have all benefitted whether we purchased the IMS solution or his motors. Given what is happening in the world around us, the merger offers many of us to continue to enjoy our ownership for years to come......Bring in on!.
P.S. I do find it rather interesting that Porsche in 2023 will open the Porsche Factory Restoration facility in Atlanta.....
If it were not for Jake, we would be replacing IMSB failures with new factory engines(or rebuilt used engines) instead of being able to R&R the IMS bearing.
He invented the tools and the procedure for replacing the IMSB.
Many people have copied his tools, but they would not have even attempted it themselves if Jake hadn't done it first.
Not every one will possibly destroy their M9x engine to develop or test a procedure.
Jake is willing to take the risk, multiple times, before he touches an owners engine.
It�s pretty crazy to see differences in opinion in the tickets and phone calls at FSI. I can see why Jake is beyond done with the opinions and bickering.
He�s not the only one that�s tired of business today. I�m currently dealing with 3 of our Certified Installers that have either sold their shops are have them listed to sell. Between the supply issues, and post- Covid attitudes people are beyond the edge.
I talked to one CFI yesterday and his words were �these people are going to keep on till all the good people are gone�. He listed his shop for sale Friday of last week and told me to not even refer the [local to him] person to him that had contacted us looking for an engine.
Some people have sent tickets to FSI today asking for info about the new program. They said �I would have definitely bought an engine before these changes if I knew they were coming�. Jake didn�t tell anyone other than those that still had engines being built about these changes. He didn�t want a flood of people jumping in to get one of the last engines.
Initially when he tagged the line he was going to just end the business altogether. A few weeks after the line was tagged he worked out a deal with LN because the industry desperately needs these engines, and we can create a scenario where there�s no negatives for him. He just manages his employees, rips the phones off the wall, deletes his email accounts shuts off social media and goes behind his iron curtain with the steel FSI gates staying shut.
That said, don�t anyone wait around for an R- Series. I know that he will take at least 1-2 years off from building any R-Series engines. He really just wants to be �left the hell alone�.
If you want to buy an FSI engine start the process now by sending in a ticket and Jud will send you an application. This way the review panel can consider the application and you can make it into the webinar on September 21st.
Currently in the planning stages with what direction I want to go and am about 2 years out from making the plunge. if going with a Raby, I obviously would put a deposit/application in a bit before then. Anybody in that FB group or on here have an X51 engine that has been sent to Raby (I have an X51 engine and am curious on the gains and real world driveability)? I'm potentially looking at the R series and curious to real world experience with one as the 996 is my daily diver. My main juggling issue here is what's the benefit of going that route vs just getting a Mezger when spending, assumingly ~$30k for the engine itself?
No deposits with the new program. I’m sure that all engine prices will exceed 30k, the current prices are all greater than that. R- Series can easily double that figure, the last ones sold were 55K and that was 9-10 months ago.
The X51 actually takes more work to get the same sort of gains when FSI takes engines bigger. With this extra work done you may as well wait for an R51 which is the Raby version of the X51. These are generally 4.1L or 4.3L
If the car has a matching numbers X51 engine and it is a special edition car the new program won't do you much good since the engine from the car is longer the engine that is built. This is how lines and schedules are avoided while staying away from mass production. Everything about the ordering process has changed so FSI can mitigate the chances of missing a scheduled completion, or blowing a proposed budget. Neither of these have occurred to date, even though everything else is late and costs more money.
If you are 2 years out and have a special car, then I'd urge you to get an application in now, so Jake could consider the project as one of the very few he will do personally when/ if he decides to. I'd say these are 2 years out from being considered at this times and I know he will only take on one car at a time when the time comes. When one is finished he will take a 6 week break while we ship the next car in, and then that car gets done when it gets done, and costs what it costs. These and special projects are all he wants to deal with.
@ltusler
is a member here with an X51 that FSI did back in 2009, then boosted up a few years later. He can probably tell you a bit about it.
That said, the FB group had several non- FSI purchasers try to fly in under the radar today. Each request is validated through confirmations to the original purchaser data base. If a name isn't validated, the request is denied.
I find it interesting as well. Makes sense as a business model for porsche to get paid again on the same car. Porsche sells you the new car, sells replacement parts over 20 years, and then restores the car again for probably the same price as was paid new, and then sells you replacement parts again over the next 20 years. How many companies can get paid so many times and so often. Wow!
What is the current process for an R-Series engine? I've owned my 996 for 18 years and have mid-run plans to restomod it into something special. I'm perfectly happy to wait 2+ years...love the car and expect to put another 100,000++ miles on it.
No current process. No orders being taken, or projects planned. They are trying to stay away from commitments of time and money altogether.
I only know that Jake is considering doing a very small number of them personally. No one else at FSI will be tasked with them. I know he will never have a “line” again.
I’ve seen no less than 20 tickets this week that were politely turned away. They just want to finish the backlog they have, and then figure out what needs to happen at that time.
Once upon a time back in 2008 I acquired a 1999 996 C2. I was the second owner, and still am.
The PO had the car since new and gradually turned into PCA Club Race car. In the form I received it, it was a 3.6 upgraded to X51 status and was dynoed at 318RWHP.
The PO had club raced it for about 10k miles before I got it. He did very well in the series and raced at many tracks around the country.
So as is my usual practice, I jumped in with both feet, and bought it. Naturally, about midway through the following season, it twisted the crankshaft in half.
So I consulted with the local racing shops in the local Porsche world and got the response, rebuild a M96?, what's a M96?
Eventually I found some guy named Jake Raby.
We got along well, and they way he spoke about the details of the engine convinced my that he was the only way to go.
So engine out, strapped on a pallet, and shipped down to GA. Jake and crew built it into a 3.8 reusing what ever X51 components they needed.
Then in November of 2009, I loaded the car on a trailer and drove to the shop. Keep in mind this is very early in the FSI engine program.
I used the FSI shop and installed the engine in the car, then we began the startup and break in process.
One notable quote about Jake's insistence that the break in process occur at his shop was "if it grenades at my shop, its my problem not yours".
So after the process was complete, I loaded the car and headed to Road Atlanta for a DE. Due to the weather I was only able to run 1 of the 2 days, Jake was there with me and only asked that I did not red line it to much it during the DE, car performed flawlessly.
It was also flawless for the next 5400 track miles. I was due to pull the engine at the end of the 2013 season and change the AOS, well guess what, yes that's right, it expired. At least it did it in grand fashion on the main straight at Brainerd International, in 5th gear at full song, its said you could see the smoke plume for miles around,
So needles to say, when cylinder #4 hydro locks at 7k RPM, there isn't much left to reuse on a rebuild.
Shipped the whole car to GA for a Stage III 4.0 build in August of 2013, received completed and ready for use in May of 2014.
So far its completed 3900 track miles. Mostly DE, but also 3 seasons of PCA Club Racing.
Please note that I am running a Motorsports AOS and Jake opened the bearing clearances for 20-50 oil. I do not have oil pressure issues. As a matter of fact, last weekend at Road America, through the carousel, the pressure drops to 3 for a bit, once the throttle is increased, it goes right back up. Having the engine build tailored to the application is key to its proper operation.
I could not be happier with the services and support I receive from FSI and Jake.
Since the second rebuild, I have also purchased a 1958 218 Standard Tractor and a 2003 996 Targa with a 4.0 rebuild in it from Jake and FSI.
I am very happy to see the merge with LN on the future services, LN has also been very supportive to me over many years.
In my opinion, you can not go wrong with Jake, FSI, LN Engineering, and Hoffman. But as always YMMV.
Wow you have had 3 FSI motors that is awesome. I see people on here saying that the M96 can't handle track use and keep oil pressure issues from happening. Jake told me exactly what you are stating "
Having the engine build tailored to the application is key to its proper operation
." I am glad to see you sharing that. I am so happy with my experience with FSI and my motor I would love to get a chance to setup another car with one of his motors. That opportunity will likely not come to pass however if i can find myself in a place where I can make that happen i would love to have an R40 or similar built. It would be great to have one of his R motors with all the work that goes into those. We can always dream....
@ltusler
thank you for the “rest of the story”.
I think your broken crankshaft is the one in that famous photo that was taken in the FSI Morgue with the crank sitting on the red table of death in 2 pieces, correct? Jake used that story to teach me about the cons of using a lightweight single mass flywheel.
After so manmy years and so much experience its good to hear this story. There’s so much talk on this site about oil control on track, and how to solve it. I’d say that FSI knew how to do that about a decade before most of these people even considered pulling one of these engines apart based on your report :-)
@2005 996 C4S
I am certain that having a prior positive engine purchase experience with FSI would put you high on Jake’s slection list for another project in the future. He alsys likes that, and at the present of the 4 engines he has been tasked to build between now and the end of the line, 3 of them are for prior purchasers that have bought another car, and want another engine. One of them is on engine #3, and that owner is Mr. Miles Collier, of Revs Institute.
That is great to hear. Well all I can hope is that Jake is doing this for a long time yet and I can make that happen. I just got my stage 2 this year so I obviously will be enjoying that for some time. Maybe I can start putting money away towards a goal of that sometime down the road. I am still dealing with comments form the wife about why I spend all this money on a car I only drive in the summer for fun that the kids can't fit into... I guess I need to get her addition built to the house before I buy another car/motor... Women and their flawed priorities! Who needs a nicer kitchen? They don't have a gas pedal to push you back in your seat and a motor that sounds like god screaming at you!
There�s really no telling. I knpw the one reason for removing backlog and not accepting deposits is so at any time he can close the doors and not owe anyone anything. Most of the employees have 5-6 years before hitting retirement age and they�ve been with Raby for more than 20 years already. If I had to guess he wants to provide them a place to work until retirement age. This isn�t official word just what I have gathered from discussions around FSI when I�ve been training there.
Seems that wives use these engines as leverage to negotiate new kitchens and bathrooms, and sometimes a new diamond all too often.
Well, as the chef in the house, *I* need a new kitchen! So I now have the best of both worlds, a Stage II rebuild (voluntary) and a sweet chef's kitchen. Wifey says nothing as she likes riding in the parsh and eating the good food.
Well my wife did get a new vehicle, a Toyota RAV4.
But she didn’t demand it or anything.
I wanted her to have a new reliable vehicle with a warranty, so if I get hit by a bus she doesn’t have to worry about keeping her car running.
I’m allowing her to park in the garage until my 996.2 returns.
She knows that her RAV4 will be evicted when my car returns.
Ive tried to make our house as trouble free as possible.
I’ve replaced a consumer grade AP with 4 commercial grade mesh ones.
The Internet router is now a VM on redundant hardware.
I’ve installed gutter guards, so no more cleaning out the gutters.
She now has a vehicle with a 7 year warranty.
I have automated (smart house) as much as possible.
I’ve been teaching my son as much as possible about how things are setup around the house.
Second bout with cancer has me trying to future proof our house for my wife.
Lucky! I need my wife as I can't cook anything. If she really wants me to do something all she needs to do is cutoff the food supply and i need to fall in line...
Best of luck Tex. I have close friends that have been where you are. Thankfully we are living in 2022 where treatments have come so far from what they were. Kick that thing and get out and rip that Stage 2!
Yuck Tex. Nice work taking care of the girl. It is our lot in life. Our prayers to you.
The reason I was able to buy the 996 is because my wife was happy with her '13 GTI. Actually she was happy with her 20 year old Toyota Corolla Wagon, but someone ran into her and killed it. So, because she's not demanding about vehicles I can take the automotive budget and do things like buy new engines and suspensions and wheels and stereos and ground effects and...
The 3.8L Stage1 is really nice. Before, revving to 6500-7000 was cool and continuously strong, but now it's much stronger and so fast and effortless. It's crazy. I guess I'll get to the point that this acceleration is routine and start itching for more. For now, it's F'in awesome. I can't imagine an R43.
Very interesting, you have peaked my interest! I know Jake is always working to find ways to squeeze more out of these motors. Can't wait to see what is coming.
Everything from the airbox to the tailpipe is going to be offered. Fully developed, and all in matching form.For current FSI owners everything will be a bolt on profile and all available through LN.
Those that don't have FSI engines can still take advantage of most of the items, but they may require the addition of FSI cylinder heads and camshafts to complete the matched combinations.
[Image-only post; no author-written text. Original image references:]
https://cimg9.ibsrv.net/gimg/rennlist.com-vbulletin/700x394/shut_up_and_take_my_money_1c78432bc29e6a5c6075730a2054aa4cd0f0271e.jpg
Follow along on the FSI Owner's Lounge. Jud will be there sending links when items are available.
This is all USA made. The X Pipe with CARB approved removable performance cats is first in line. These are done for the 996, and just awaiting the cats to be made.
The airbuses are the big focus now, the composites shop has 3 of them being assembled this week.
Given all that is happening in Germany, especially with energy problems, LN producing proven and improved parts.....why this may be salvation to many of us. Perhaps this may just start a special class of refined Porsches......
This is a driving factor behind the FSI/ LN merger. LN has added a ton of resources for in- house manufacturing during the Covid 19 period. FSI building fewer engines, and making each more specialized has opened up their resources for invention, R&D, testing and other forms of development to us to benefit from. This not only puts Jake where he wants to be, but it gives us something that isn't found anywhere else in the Porsche industry under one marque.
The shortages are "NLA" parts are here for the long term, so we either make up for the inadequacies of the supply chain, or everyone suffers. All these products are made in USA, either in Illinois, Georgia, Wisconsin or North Carolina. We are keeping everything at home.
Here is another pic that Jake posted. Also quote: After this article was written in October of 2008, they experienced a rash of similar issues related to broken crankshafts and as an update, in September 2009 they did not experience a failed crankshaft from an engine using a dual mass flywheel............
It was caused by not having the new flywheel balanced with the existing engine and created an imbalance. The crankshaft was forced to absorb all the harmonics.
Yeah, I remember when light weight flywheels were the rage for faster reving. My indy kept telling me no, not for the 996. So I never did. Your pictures certainly tell the story.
Yeah, for a guy like me who has no wrenching skills, they have steered me in the proper direction since day one. Bought lots of beer, whisky and cigars for the guys over the years.
On the flip side my 3.6 FSI built in 2015 for my Boxster S is running strong with its LWFW . The difference is Jake balanced the rotating mass to race spec balance . She revs smoothly and quickly I love how it reacts to throttle input . Only downside is gear stack clatter at idle with your foot off the clutch . A small price to pay in my opinion .
That's only because you have the R51 combination that utilizes the largest M9X bore size on the planet, coupled to a de- stroked crankshaft that is super strong. Increasing rod journal diameter along with main journal diameter while also reducing stroke makes for a super strong component. No one else here needs to be confused in believing that FSI will ever approve the use of an LWFW on any other engine in the future. The R51 will make power past 8,000 RPM due to this radical combination. I learned about this combination recently:
You Tube
Destructive inspections of all the different crankshafts and connecting rods are being conducted next week. Jake wants to dedicate a chapter of his performance book to publish the material specs and changes in each crankshaft as the components were revised across the 11 years of production.
This is what Apple is doing with their iOS . There are 1.5 billion devices currently working so they get you in the different services, one day in the future their revenue from services will exceed the I phone.
Yes we always itch for more power. According to this thread an R is like $55k, you can buy a turbo today for that money before they take off to the stratosphere. The mezger turbos are almost bullet proof. Saturday I tested a gt2 ruf modified and it was awesome, the funny thing is when I finally decide on the final tune for my car I�ll be at 600 whp faster than the gt2. I only have like $2-3k more to spend to get there. Yes I already did remodel some of my kitchen and yes I�m the cook. I would die of hunger if my wife�s was the cook. Not telling my wife, I got her a 21 MB 300 GLE in December, so preparing for my future turbo purchase which I got done in April. Now more house renovation stuff.
When I first saw this vid, I just about creamed my shorts and immediately contacted JR about the possibility of getting this done to my 3.8. He said it's not for me and my street car due to the power band being moved up. Low end TQ just wasn't there. For a track goer though, I bet its incredible.
Not true.. Many GT3 engines were damaged by LWFW (RS) being installed. So many infact the Porsche issued a TSB on this exact subject and warned the dealers to tell their customers NOT to install the single mass RS flywheels and that any damage would not be covered under Warranty..
Dual Mass flywheels were designed and installed to absorb the unavoidable harmonic vibrations..Otherwise they would not be used at all since they have no performance advantage whatsoever..
On the GT3RS and CUP engines they take/accept the risk and Porsche also charges up front for the liability/damage they know will come in a certain percentage from the unavoidable vibrations...
Factory Porsche engines are not really balanced all that well from the factory, your lucky if they are balanced within 3 grams...The RS and CUP engine MAY take a little more time in the balance department, but a good Race shop will get the balance a lot better( to .5 grams) . But there are always unavoidable harmonic vibrations..
I don't have access to TSB's anymore, but a quick google search did turn it up for you...
Technical Information
Service
36/08 ENU 1360 1
GT3 Engine: Flywheel and Pulley
Vehicle Type: 911 GT3 (997)
Model Year: As of 2007
Concerns: Flywheel and pulley
Information: Replacing dual-mass flywheel with single-mass flywheel.
We have discovered that the dual-mass flywheel, which is installed as standard in the GT3 engine (vehicle type 997810/-811), is being replaced in the dealer organization with the single-mass flywheel from the GT3 RS engine (vehicle type 997850/-851).
Information
Due to an increasing number of reported faults, we expressly wish to point out that the installation of the single-mass flywheel (from the GT3 RS) in the GT3 engine is not approved by Porsche.
Since the 911 GT3 (997) engine application is designed for the dual-mass flywheel, conversion to the single-mass flywheel results in the following problems and consequences:
� The single-mass flywheel causes fluctuations and vibration in the lower rpm range, thereby reducing the smooth-running performance of the engine.
� The crankshaft is subjected to one-sided loading, causing stress peaks that can result in damage to the crankshaft.
� The one-sided loading of the crankshaft can cause the pulley to come loose, resulting in damage to the belt drive and engine.
� Any damage relating to conversion or damage that can be attributed to conversion is not covered under warranty.
Please advise your customers of this information accordingly.
�Porsche Cars North America, Inc.
Yeah, I'm going to start counting on
@Dr Strangelove
for all my TSB back-up documents...lol ....He is the man !! Just hope the ones I want to bring up when people question my word are still in the archive..
You good now??
I'm beginning to think that if you aren't a long time 996 owner from back in the early 2000s, you've missed a boat load of "real time" info that came at us from Porsche that is just a garbled mess today.
The Essential Companion certainly helps to clarify. So if you don't have a copy, it would be smart to get one. But we need another book that fills in the holes over the last 10 years.
In the submission tickets I see guys all the time that do not want a newer car, or a Turbo. They want the car they already have, and they want to keep it forever. This is why they consider the FSI engine to be an investment that has merit.
I can understand that because I taught I would sell my early 99 �Jakes favorite �
after I got my turbo. I�m keeping both. They are two different experiences, the coolest thing is I get to compare them in my mind back to back because I can constantly drive them both. To be honest and fair I haven�t test driven a Jake Raby powered car. I�ll probably experience that in the future with Tex squirrel 🐿 car. To be continued.
I get to go back and forth between my 997.2 FSI 4.0 (daily driver) and my stock 996 4s and both experiences are significantly enhanced by the different ride each offers. I will never sell Jake's beast of an engine, the 4s might go someday but I doubt I'll ever actually part with it. Dr Jekyll and Mr. Hyde will be garage mates for a long time.
@Sam-Son
Previous owner sent it to FSI in 2019 with bore scoring and commissioned the 4.0 build. Jake posted a Rennvision video of the engine interrogation. After a subsequent PDK failure I stepped up and bought it. It subsequently got a brand new FSI 4.0 stage II engine installed for reasons I won't go into but Jake and LN will always have my total respect & admiration, as well as any business I can give them. I've put 20k miles on the new engine and it's everything it's cracked up to be and then some. My favorite stretch of nearby interstate is a newly paved 5 lane highway with a steep, nearly mile long, incline. Taking the 4.0 uphill at 140 is glorious.
Yeah, That was my expression when customers with Turbo/GT3 would ask me about the noise...lol
I confirmed this with a Porsche Technical Instructor at P10T Training back in the day..I asked him "whats causing the pea-thrasher noise in the Mezger engine?" He said "what noise?" I said " the noise that they all make after about 30k miles, that sounds like a pea-thrasher, coming from the front of the engine where the timing chains,oil pump intermediate shaft, gears, are that goes away above 1300 rpm?" , he said again with a smile "what noise?" lol....I took that as IT IS WHAT IT IS..lol
Just like the gear clatter all 996's make from the trans if you put in a LWFW..the noise does no harm, just a nuisance.....
I've been searching for an x51 airbox...when jake said he was going to make a version of it i stopped looking...can't wait to mate one to my FSI stg 2 4.0L 🤪
The composites are being done this week for the production parts. This requires a 3 piece mold to end up with a part that is strong, light, and utilizes the mods that Jake has found beneficial to the routing of air inside the box when adding displacement and inlet port flow capabilities.
The altered pieces to maintain the proper MAF sensor housing diameter and critical features are being multi jet fusion printed next week. Air filter housings are in the printer today.
This is a lot more than a recreation, but some features are being maintained because they are critical to proper operation.
Once these pieces are made the only thing required is one final high depression flow test to prove the production part has overall maintained the benefits that were integrated into the design. This is easy when we have both components to test back to back on the flow bench and dyno together within a matter of minutes.
Thank you!
Honestly I view this more as half CYA on Porsche's part. It seems like quite a few failures had to do with installation (sheared FW bolts/etc) than internal issues. I find it hard to believe that a properly installed factory part on what is basically the same motor would be an issue, but whatever the cause was, it was enough for a TSB.. so, fair play.
In my experience lunched bottom ends happen quite a bit from lightweight crank pulleys removing the harmonic dampening properties of the OEM unit, never heard of it from the flywheel end of things until now. I need to
I total disagree . Flywheel/clutch jobs. are one of the most routine jobs a professional Tech does. They are wear items that every car will need at least one of unless it dies early, and many cars will get quite a few of this job preformed on them..
It's inconceivable to me to point a finger at the installation, no Tech that I know of would dare to use the wrong flywheel bolts or torque technique on a high RPM engine..
Most of the Mezger failures I have seen from installing the RS flywheel on the GT3 engine were from the vibrations causing the front pulley to come loose and damage the crank. The front pulley is very thin and light with just a dowel pin and the center bolt that secures it...If the vibrations hit the right pitch/frequency , the front pulley becomes unsecured..
The effect of harmonic vibrations and even sound waves are a Science all there own...The DMF eliminates a LOT of harmonic vibrations.....Playing with them is playing with fire !! .. you better have your Big Boy pants on if you do....lol
Definitely once the engine is broken in.
I'm afraid to ride shotgun with Luis.
I do have a dash cam video of Luis on the shoulder discussing freeway speed limits with local law enforcement.
Luis took off driving triple digits and left me behind since I was "just" driving 90 on the freeway.
This was right after our header swap.
When Luis says supersonic, he just means 130+mph, not actually 768+MPH.
Very easily!
The airbox is a direct bolt in. The deck lid does require a couple of mods, but the pieces to adapt it will be included with the airbox kit.
The full intake system does require the engine being dropped to bolt it on, and at that time you may as well add the LN/ FSI R3900/3905 cams with matching springs and retainers to optimize the combination. These are always good options when you start getting used to the power, and want even more.
with my Parts combination my turbo is going over 625 hp easily. This is going to be the SuperSonic plus edition. A guy on the turbo forum said his car was doing 149 in the half mile, wonder what mine will be doing in the Texas mile.
I�m not doing this, I�m doing actual dyno tuning, I have an exhaust, intake and headers on top of this, that�s why I�ll be spending the money on the custom tune.
I wonder what the gear limit is on your transmission.
On the stock 996 C2 G96.01 it's 186.
With the 3.00 pinion it should be 212mph.
I'll have to research to see what your turbo's top speed should theoretically be with enough HP and runway.
OK, I had to look it up and run the numbers.
According to what I found, your turbo's gear ratios are as follows.
1st: 3.82
2nd: 2.05
3rd: 1.41
4th: 1.12
5th: .92
6:th .75
Final ratio: 3.44
At a 6750 maximum RPM (I didn't realize the turbo did not rev as high as the GT3 or even the M96.03!) and assuming a 25" tire diameter your top speed gear-wise would be 194.59mph.
You just need the HP & distance to get there.
Have put around 12k miles on my 4.0L Street Performer over the last 2 years. This weekend, I rented a 992 Saturday and took it out into the SoCal canyons. Sunday, I did the same roads in my 02 C4S. Have to say, I had more fun Sunday. Kinda sums up my happiness level with the FSI engine in my car!!
The new items are only going to be sold by LN for engines that have already been completed. The last time I brought up the idea of amending proposals to add the new items to cars that were coming through under the old program, the idea wasn't well received. I know that Jake's goal is to never up-sell anyone on anything, and he just wants to get to the end of the line being able to say that they met every expectation that was proposed while staying on time and on budget.
Once they propose something, it is written in stone. I learned quickly to never offer up opinion about an alteration of that.
Guys, remember that top speed is greatly impacted by aerodynamics. You may have the gearing and RPM to get to a certain speed, but you may not have the HP at the right RPM to break the aero wall to achieve that. Driving a 3.8 FSI Stage II 8,000 RPM capable Cayman to 186 MPH (while the owner in the passenger seat) was quite revealing. That one was built in 2011 has 80K miles on it, with around 3,000 of them being around Road Atlanta.
Stock 996 Turbo's will hit 300kph - that's quite a thing in Germany to do that on the Autobohnen, there are videos on youtube. Porsche claims 189MPH top speed. I've had mine going 132MPH on the track (need more track, the straight is only 1700 feet long). I won't drive irresponsibly on the highways around here, too much traffic.
Will there be an announcement as these parts become available? I have a 3.8L Stage II with an aftermarket airbox that I'd really like to replace with something better! Oh, 33k miles on the engine and it still screams like a banshee!
Luis and I were talking about the about the Texas Mile.
It�s held at an airport.
1.5 mile runway with a 5280 feet acceleration zone and a 2640 feet braking zone.
I won�t drive that fast on a US roadway either.
I�ve driven 160+ on the Autobahn in Germany, but US drivers are not nearly as safe as German drivers!
Mrs. Raby's Land Speed records were set in a 996.1 factory aero car @3.4L making 300 HP at the rear wheels. In the standing mile she was just a hair under 153 MPH in one class, and high 140s in the other 3-4 classes. These are just some general comparisons for aero/ HP/ distance. This was around 2007-2008 or so and I don't think the car ever had an engine bigger than 3.4 fitted to it.
If you are on the Flat 6 Owner's Lounge on Facebook there's a ton of chatter back and forth there. Jake has been making daily updates there with his testing and modeling of the systems. The intake runners and common plenum are in check print right now, and after 50 hours in the printer the runners are only 40% completed. He's been going live from the flow bench and 3D printer often in the group. Check in there. It will blow you away.
As for ordering the pieces, I am sure we'll have them on the LN store once he gives us the green light that his work is done and he has the data he is looking for.
The airbox is the first part we'll have I am sure. I know the composites (carbon fiber) shop is laying up 3 of them right now, and we have the MJF manufactured air filter housings, MAF housings and etc all completed for those 3 units. The max we can turn out is 3 per month.
The FSI camshafts are also coming very soon, we have the 3900/3905 grind being ground first, and the others will follow in the next couple months. Jake made these up as he needed them for engines, so it is taking a while to get the production turned up to meet the new demands that the increased availability of retail sales has created. Some things will be rolled out around the end of November, but most of it will hit in spring of 2023.
I know Jake has expressed his opinions on airboxes in the past on the forum so I'm excited for the opportunity to add what he develops onto my Stage II. That will add real horsepower. But only 3 per month? Gonna be a big backlog when those babies hit the market.
I'm not eligible for the Lounge, not the original customer of this engine, purchased it from the estate of the original purchaser, so i can't follow the dialog. But I'm sure it's mouth-watering.
I had the 99 coupe at 160, I took the turbo to 169. Both cars real nice and stable at those speeds. My research says that I can get the turbo to over 600 plus hp with the goodies it already has, I just need to get fresh plugs, coils, fuel filter and make sure there are no boost leaks prior to doing the dyno tune.
These airbuses are not mass produced. Our composites technician is a one man affair. He primarily does NASCAR prototype work, but works our items into his schedule.
These are not going to be cheap due to all the pieces needing to be made, (via CF or Nylon12 with the MJF process) and nothing being shelf items. To make one air box requires a total of 5 CF molds, 3 of which being the main body, and the remaining two being for the air filter housings.
The price alone will certainly keep the sales numbers down.
Jake has made it clear that there will be no more deposits, backlogs or queues with his items. I expect once they have completed a unit, or 3 that we will be given those items to sell first come, first served at that time. This way the stress level is eliminated and things are simply done when they are done with FSI not being indebted to a purchaser. This way no one ever gets an excuse of "it'll be done next week" over and over again while dates are missed. This way if production prices change, the retail price can be adjusted so no one loses out, or gets an unexpected surprise. This is the same way FSI engines are being sold in the future, nothing else provides a guaranteed method of production or purchase with no hidden costs, risks, or potential delays.
This was posted in the FSI Owners Group this morning. Looks like Jake will have a finished check print by the end of the weekend. This way the system can be fitted to the engine, and car as well as tested on the flow bench before the first production printed parts are produced.
FSI RX39 Intake Runners during the check print process before going to production via Multi- Jet Fusion
Wow! 3D printers have changed everyone's game. To be able to print this, test it on a flow bench, then test it on a car in the same shop is quite powerful. No waiting for shipments or feedback or negotiating around test data. Can't wait to feel the results! My understanding is we'll have the full monty available: Airbox, Intakes, Cams, & X-pipe(CARB compliant). I'm already selling stock to prepare for the release...
Yes,
The cams are finished and have been for a few years. They are also a low production item that are ground by a small one man operation in the hills of N Georgia. This shop is where a lot of the experimental NASCAR cam work is done. The kind of place without a sign, no commercial listing or etc. Just a guy and his wife. When I went there to pick up some cams I thought I was lost and ended up on a cattle farm.
Full intake from the cylinder head ports all the way to the airbox inlet, headers and X pipes, and matching camshafts. I think the only thing that FSI isn't releasing are mufflers, because they typically find the Fister mods to be more than adequate. These don't drone, and don't internally fail like many of the aftermarket units.
Have Fister mod on my Stage Ii and they sound perfect. Nice growl when engine is angry and pleasant when cruising.
I would expect a Jake-developed airbox to be expensive, and perfect. Wont be shocked when listed.
My car happens to be a tip, is a tip version of the intake section planned? Has the little breather pipe for the transmission "vapors".
It is getting a workout and is loving it according to what I've seen produced using it. Next week it will be printing an Aircooled cylinder head model that will be a 12 day print. The runner check print should be done Sunday evening, which will make it a 6 day print.
As for the air box and a tiptronic:
Expect that the tips will see an additional component to handle the task that you've mentioned.
I had a Phase one performer 4.0 engine built by Flat6 Innovations...and I am very happy with the performance and reliability of this engine. Sadly I lost the jump drive with the engine specs and Flat 6 can not retrieve them (not their fault) I was hoping for someone who had the same engine build share with me their specs.
I am getting a FSI stage two track performer in a month. The engine is currently being manufactured and I'll ship my car down at the end of May. I have bored scoring in at least two cylinders in my 2004 996 CS4 anniversary edition cabriolet. I have 150k miles on the car but the engine was replaced factory direct under warranty in 2010. Love the car and looking forward to it's second life. I already have replaced half of the car, in for a penny in for a pound. I am really looking forward to the stage two engine and would like to hear your comments after a few years with the engine. Can't wait to have mine.
I've had my Stage 2 for a little over 2 years and have put just under 10K miles on it.
Surprisingly it feels significantly stronger now than it did immediately after the initial 1K mile break-in.
Jake said it would, but WOW, it's better than I expected.
Performance difference (0-60, 1/4 mile) before/after the build was significant as verified by a Draggy.
But the new engine has a new performance issue.
Before the build I never had wheel spin in the dry with Michelin PS4S.
After, I have an issue with wheel spin off the line.
But the 0-60 times did drop around .8 second even with wheel spin and 1/4 is about a second quicker.
I would have put more miles on it but I work from home now and any time I go somewhere with my wife, we take her SUV.
My car is a drivers car.
It's definitely not a cushy passenger vehicle.
When I drive it, the drive is just for me to enjoy.
I've driven a few turbo 996s lately and mine is faster than a stock (and mildly modified) 996 Turbo.
I have driven a wildly modified 996 Turbo S too (GT2 spec) and it has a significant turbo lag that make it feel sluggish at first, and then it does a lot of catchup.
I really do enjoy the improved torque down low and the linear acceleration of my Stage 2.
Stage 2 here as well, coming up on 15K miles. You can listen to us sing the praises of the engine but soon enough you will feel it for yourself, and that will be the *true* revelation. You will not be disappointed.
Consider upgrades such as x-pipe and headers, and get the car tuned.
Follow the owners' forum on FB.
DRIVE IT!
I have a lowly Stage 1 3.8 from Jake in 2019 in my 2005(996) C4S. You would have to steal it to get it away from me!! Best car decision I have made in my life which covers over 6 decades.
Yes definitely going to get the engine tuned. Do you have any idea on the header upgrade cost? Also hearing the engine is loud, lol. I am kind used to loud with the top down and engine revving but my m96 engine isn't that quiet. From the videos I seen it's a smoother sounding engine then the stock but revs higher
I'm at 25k miles on my 3.8L S1 engine. It is so(ooo) fun. This engine never fails to make me smile. I drive the car daily, mostly highway 50-90mph. Like
@TexSquirrel
, my engine got continually stronger up through 10K miles. Then I started the upgrades that
@wdb
talks about
: exhaust. First X-pipe. Faster throttle response, some power gains (arguable as data is from notoriously inaccurate butt dyno), change in exhaust note to more exotic. Then headers. OMG! Huge change. I also added the carbon airbox. Then the TUNE. Amazing change. I think I'm at the top of what this motor can give based on the signal from the MAF. It tops out at 6500rpm. The heads and cams are limiting air into the motor as seen by the MAF. It's crazy! So, my recommendation is to make these changes piecemeal so you can enjoy the change that each upgrade brings. It's a really fun process. The question is 'when to tune'. I waited until all the external upgrades were done.
Most engines seem to peter out around redline.
My Stage 2 pulls strong all the way to redline.
The redline is the same as factory on the Stage 2 engines.
They are built where they could rev higher, but there�s no need to.
Shift and they pull hard from there.
Cost-wise the FSI/LN offerings are on the high side. The reason is that they have been vigorously designed and tested, they are US-made with top shelf componentry, and they don't make very many.
Sound-wise you shouldn't notice a big difference if you don't change any of the exhaust components. It will definitely be smoother due to dynamic balancing of the engine internals. Rev limit is unchanged -- unless you sweet talk Jake into building you an R-series engine...
I noticed a huge difference in the exhaust at idle.
The exhaust is much more forceful when standing behind my car when it's idling.
I've had other car guys notice it too.
Well, that makes sense. Seen the same type of stuff on many of my various engine rebuilds. Ign timing really changes the sound' of exhaust at idle.
A good sealing engine really pumps some air thru....
Is a stage 2 comp ratio bumped up with piston upgrade,? do they install
Schrick cams
in a stage 2..?
Sounds like you've got an engine sealing its cylinders very well and rings have seated nicely....
sounds like a sweet engine.
Enjoy...!!!
Definitely going to get the x pipes. I am thinking about header and airbox upgrades but don't want to break the bank, and I am not sure what's used in the standard build. Do you know ball park cost of upgrades?
X-pipe is where you will see the best gain, plus it will improve the exhaust note. Honestly though any of the bolt-ons will provide the best gains if you have an R series engine; the stock items are pretty good until you are really pushing the limits.
That airbox is dead sexy to look at though!