3.4 or 3.6 engine for winter DIY,

I:Interested in a full long core 3.4 or 3.6 engine for winter DIY, saw that some folks were selling to junk yards or turning over to insurance companies. I'm not a commercial enterprise, recently retired w/ 2 older 996's and would like the experience of rebuilding an engine. thoughts???

Why not make a deal with a local wrecker or yard, have them let you work on the motor, you supply parts and labor, and when it's rebuilt you guys split the profits on sale. Since theres such a small market for internals on these cars, I imagine they wouldn't be missing out.

You may want to have a look here, if you haven't already: http://www.youtube.com/profile?user=...6s&view=videos This guy has a whole series of videos rebuilding a Boxster S engine. Might give you an idea what lies ahead.

I just did this at school. Its not too bad with the right factory tools. Without them i have no idea how you would do the wrist pins, and cam timing ect. Check out video 5 from above... Oh and he put the wrist pin c-clips in upside down....

We have alternatives to the factory tools. We rent these, sell these and include them in our DIY engine component assemblies that come ready to assemble, fully balanced, fully upgraded with big bore possibilities and with support :-)

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cardsrule, where did you go to school?

I go to school at Porsche here in Atlanta. I am half done with PTAP program. When i am done i will have 72 credit hours. I love it!!! I can't wait to get to a dealer and start working on theses cars full time.

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That's great. And then you can go off on your own and make a killing (Kind of like Robert at Redline in Tempe...do you know him? Great guy and great shop (he is an ex premier tech). Good luck.

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Its interesting that Porsche is now teaching the internals of a M96 engine now. I didn't think they taught rebuild for the M86 or M96 in the past.?

Yep we have done m96, m97 and both cayenne engines. They have an aircooled (m64) class but we don't get into those. Scott, I have heard of him but i have never met him. I am just excited to get to the dealer. Sorry for the hijack. If you guys ever have questions feel free to pm me.

Can anyone go to this school, or do you have to be looking for a job at the dealer? Are there any other schools that teach Porsche specific classes?

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From what I have heard from my Nephew who was going to go through Mercedes-Benz school is that you have to stay with the program until the end, which is about a year. If you don't, it is $15,000 out of your pocket. Of course, you have to go through Universal Techinical Institutes program first. So in essense, I doubt you could sign up for the M96 class .

You can here!!! The new facility has 1500 square feet for training up stairs.. Individuals and Porsche mechanics will soon be able to come here for 1-4 day periods of instruction on the M96 engine.

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Someone buy Mr. Raby a membership.... Awesome!!!

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Wow Jake, I didn't think it could get any better. Your going to be seeing a lot of me

Jake..that sounds pretty cool. I had a blast tearing them down and putting them back together. Tippy is pretty close to how my school works. I had to go to uti for a year and a half to get in to the program. They only take 20 people a year...its really hard to get into...

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Good job! We need some good mechanical knowledge for our cars.

AND We'll be offering step by step instructional DVDs produced in house as well. Things are getting much better for the M96, Boxster and 996!

Jake I want to ask you some questions: One of my friends is an independent Porsche specialist in Madrid (Spain) He works very very fine and learnt all about his father, who was an eminence in Porsche Motorsports 30 years ago. In Madrid Porsche owners who love our cars don't leave our cars in offcial Porsche dealer because they don't work as they ought to. My friend usually do reconstruction of air cooled engine with care and the clients are always very satisfied I'm going to talk to my friend if he wants to begin with your program and being first specilist in Spain who could offer an upgrade M96 system from yours. Would be any problem to purchase the internal pieces from Spain? Are you doing a special contract to get exclusive deal and support? Thanks It seems to be very interesting

One more question about the oil filter you made: As my technical english isn't enough rich to understand properly, I'd like to know the way this filter works. You say in your web: This also makes changing your oil a much simpler (and cleaner) task. No longer do you have to handle changing out the cartridge, worry about contamination of the oil filter housing, or thinking you have cross threaded the cheap plastic filter housing! So, Do I replace the OEM plastic oil filter housing for this one? And , Does your new oil filter housing fit as eternal piece?

Tippy...I know alot of people have bad opinion about dealer techs...I am going to do all i can to change that. I have pretty much dedicated my life to these cars (and i am not just out of high school...i got a college degree and left a very good job to get into this program) and plan on doing the best job i can on theses car everyday.

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This piece takes the place of the current plastic outer filter casing. See the part with the threads and the rubber o-ring just like the current filter casing. The first picture shows a Black oil filter partially threaded onto the unit. WIth this piece installed you buy/use a different style filter that threads into the golden looking threads... A spin on filter like most cars use. The question I have is how does this allow/facilate the use of an accusump? Is there an oil port on it somewhere? Thanks -Paul

Thanks Paul So with this new oil filter housing, you must use a different oil filter. Would it be easy to purchase? or , Must we to order the oil filter to Jake? I think you talk about this type

Yes, the filter is a standard spin on that with the adaptor takes the place of the plastic housing and cartridge. We include one filter with the kit, but there are two alternatives off the shelf that can be bought at any auto parts store. No more necessity for Porsche parts. I am less than satisfied with any plastic part thats in my oil system, it yells CHEAP and trouble at the same time. One of the units does allow the accusump to be attached as it has a tapped fitting in the inlet and outlet of the adaptor for a easy access into the main oil system of the engine.

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Another doubt: So in the piece which susbtitutes the plastic housing we must change the rubber O ring every oil change, apart we change the oil filter too. Must we? Jake I want to ask you some questions: One of my friends is an independent Porsche specialist in Madrid (Spain) He works very very fine and learnt all about his father, who was an eminence in Porsche Motorsports 30 years ago. In Madrid Porsche owners who love our cars don't leave them in an official Porsche dealer because they don't work as they ought to. My friend usually does reconstruction of air cooled engine with care and the clients are always very satisffied. I'm going to talk to him if he wants to begin with your program and being the first specilist in Spain who could offer an upgrade M96 system from yours. Would be any problem to purchase the internal pieces from Spain? Are you doing a special contract to get exclusive deal and support? Thanks It seems to be very interesting Here is a link to my first post in rennlist (My friend independent Porsche specialist): a complete translation of my friends engine magnesium rebuilding job

The rubber O ring and the entire adaptor says installed onto the engine permanently.. All you change is just the spin on filter, like most any other car... Its much cleaner and offers better filtration AND it removes plastic from the oil system. We are assigning international agents now, I'd have no problem dealing with your friend in Spain, we ship world wide daily already.

Thanks Jake I'm going to talk to him about this.

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Ok I guess there are no core engines out there on this forum, I had thought about getting a "non overheated " core (blown) engine to jump on Jake's bandwagon and go through Jakes and L&N engineering process, and come out the other end with a bullet proof 3.4 upgrade spare engine, or an install in my 99 or 01 996. Guess it wasn't to be, salvage folks i've talked to wants way too much $$ for what I was told not to get overheated core due to possible head damage, nothing else seem available.i.e... ims, chunking etc Thanks Jake for the telecon info, I'll keep looking Roy Seyferth

Roy, We have core engines... The salvage guys part the engines out and make 4X more money than they can by selling them to you as an assembly.

This thread and Excellence magazine article are one of the best discussion we had in the last year. I love technical arguments.

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Thats really cool. The way the economy is, it is good to be diversified in different fields. I somewhat manage continuous improvement where I work but am also a certifed aircraft/powerplant maintenance tech.

I really hate technical arguments as I generally engage an opposition that has no first hand experience with the topic at hand, having generally educated themselves with a book or other form of reference thats not "Real". I gather my own data and my own understanding and only believe what **I** see or what I **HEAR** from the engine personally.

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Jake, When would it be available the special oil filter? TIA

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+1 for when are these going to be available and ? not being familliar with accusump, how do I know which one I need... with or without? Ed <PS I hate plastic engine parts too>

We are "pre-selling" the adaptors now... They will be ready in a couple of weeks. We are working on a full accu-sump, oil cooler kit for the 996 and Boxster. No guess work, just bolt it on. That'll be around 1K.

what's an accu-sump ? and will the adapter alone be 1k? (seems a little high for a piece of 6061 turned, threaded, drilled and anodized, even if you have a 16 finish on all surfaces)

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Please Jake, Could you tell us a bit more info about this? TIA

NO! The oil filter adaptor will be only 159.95. The accusump, Setrab oil cooler and adaptor KIT will run around 1K. An accusump is a unit used for wet sump engines that equalizes system oil pressure when cornering G forces move the volume of oil away from the oil pick up tube, rendering oil starvation. The accusump discharges fresh oil when the system pressure is lower thatn the charge pressure in the accusump. Once the engine regains pressure the accusump recharges and is ready for action again when/if the starvation occurs. These save the lives of wet sump engines.

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Fantastic! You're improving the qualities of M96 engine! Good job Jake

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Very inovative concept/solution for the oiling issues that we suffer. I look forward to hearing more about the accusump when it comes out.

I've just receive the magazine. I find the article very interesting. I'd like to see any pic of the accusump. Jake, Do you have anyone ? Another question: I read in the article about the rubber oil-control windows. I'm trying to understand what an oil-control window is... Is it an oil separator? I think It isn't but don't know what is

The oil control windows are located in the engine's oil sump and work to keep the oil confined to the area closest to the pick up... These are made of rubber and time is telling us that the material doesn't like heat, engine oil and fuel intrusion. We replace them with stainless steel upgraded versions.

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Thanks Jake My friend (Porsche specialist) is very interested in talking to you. I told him about your program. Could give your email adress in a PM please? I think you'll have a new affiliate in Madrid (Spain)

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Dangit! I knew I should of made one of these and sold them. Good luck on the venture. These have been around in drag racing for years.....

Thanks.. My email address is [email removed] I'd be interested in chatting with him concerning possibilities.

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Hey Jake, Sounds very promising. Will you offer various size accusump or will one unit fit all? Canton makes the accusump in a variety of capacities. Also, will your kit use the manual engagement switch or the electronic switch? Best, -Paul

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How does that compair to this http://www.ogracing.com/catalog/2-Ca...CHE-996BOXSTER I have this installed on my car.....

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That kit tries to encapsulate the oil around the pickup whereas the method Jake has will pressurize the oil system if oil pressure drops through a accumulator. The accumulator simply fills up with oil and compresses a spring inside. If oil pressure drops, the accumulator bleeds off its oil supply to ensure temporary pressure is maintained.

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Actually all the BK kit does is make the oil sump a little deeper allowing you to carry 1/2 quart more oil.. Nothing more. It actually works against containing the oil near the pickup by completely defeats the factory baffle (the black thing that looks like a box). Oil now freely sloshes out the bottoms since you raised the containment piece up and didn't seal under it. Absolutely worthless if you ask me. What they needed to do was make the sump deeper allowing the containment area to hold more oil and also lowering the oil pickup by the same amount.. Like what Mantis Sport did. -Paul

The issue with the BK kit is that it does not include an oil pick up extension... We do have one of these that can be added to the BK kit, or we sell our own as well. The BK arangement also uses the factory rubber oil control windows as well as the plastic containment package. Our goal is to remove rubber and plastic from the internals of the M96 engine wherever possible as it is failing over time. The accusump is a pressurization system, when the oil pump loses prime in a corner the accusump accumulator will discharge filling the system with reserve oil thus saving the engine.

quite an awesome thread and the youtube videos are nice! the 4,5,6 pistons look kinda scary to install though. haha

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candidate is just an engine that has worn out. Still runs but is worn out and down on power. I rebuild a Dodge V8 318CI engine in my pickup truck that was so worn the valve lifters were clacking. Upon teardown I found several cam shaft bearings just gone. Worn/corroded away from probably lots of idling and infrequent oil changes. (The pickup was bought used from a guy who bought it from CALTRANS here in CA.) After a rebuild consisting of valve job, new camshaft, cam drive, bearings, lifters, oil pump, rings, oil pump, water pump but no overbore bore and no new pistons -- I hand honed the cylinders to clean them up and while the piston/cylinder clearance was towards the large side still within tolerance -- after reassembly the engine ran so smooth more than once I tried to start the engine when it was already running. Stay away from engines that have suffered stress end of useful life events: overheating, severe loss of oil flow/pressure, mechanical failure which infuses engine oil passages with metal debris that is hard to ensure all is removed before engine reassembly. Sincerely, Macster.

Seems you should spend less time on this forum, and more time answering phone messages and emails that could lead to business, JMO.. I for one, will go elsewhere Roy Seyferth Warrenton Va.

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Ouch

To date I have returned EVERY phone call that we have received and I only have ONE email in my inbox that has not been replied to- it was received yesterday afternoon. Have you attempted to email me? Call me? If so, and I have not gotten back to you, it wasn't for any other reason than the fact that I didn't receive your communication. I will say that I have been VERY busy getting our new facility completed and there is always a possibility that I simply forgot to call you back, didn't get your email or tried to ring you back and missed you.... Either way, lord knows that we certainly appreciate communication and I do my best to return EVERY call the day that I receive it. With the current article in Excellence that means that I may have to field 30 phone calls and 75 emails a day on top of finishing a new facility, component and engine development and also manage my Air-Cooled division as well.. I'd like to know how yiu tried to contact me so I can ensure that no one else's communication is lost in the shuffle in the future and I'd like to apologize to you for not responding to you promptly.

Very interesting thread for all Boxtser/996/997 owners. I have been contemplating and looking for the oppurtunity to buy a aero 1 packaged 996 but have had some concern about the engine reliability problems that always seem to come up when perusing the 996 forums. After reading the Excellence article I was heartened that building a reliable 996 engine that would see both street and DE duties was a viable possibilty. I have to applaud Mr. Raby and crew for digging into this series Porsche engine problems to give current and future owners another alternative than just getting a replacement engine from Porsche. To have Mr. Raby come on this list and try to answer questions about his new products is not only good business sense for him but also good for all who want to learn more about their engines. Cheers, Constantine