Ross' 996 turbo

Ive been lurking and stealing advice on here for a while now so figured its probably worth putting up some pics of where im at. About a year ago i thought id pull the pin on a childhood dream, had to have a 911 turbo at some point in my life. Hoping the time was now. Looked at a few cars, emailed a few people. Some people replied, some people were pretty rude, eventually found this one down the road about 100 miles from me so went to have a look. I knew it was in need of some love but thats fine, im no stranger to spanners. The chap selling it just didnt use it anymore. A few things came up on the test drive but i used that for bargaining and agreed on a price. Got the train down the next weekend and picked her up, drove back up the road with no dramas Porsche life by Ross Elder , on Flickr With sports seats Its a 2004 996 turbo with 91k on the clock, im the 3rd owner, first owner was full OPC servicing and work, 2nd owner used a well respected indy. I had a good look through the receipts and it all looked good. Had photos sent of the underside of the car and it seemed to be in reasonable condition. When i got it home i started looking deeper and realised all was not well, one of the turbos actuators had broken off, ill hold my hands up, i missed it and having never driven another one of these i didnt know what to expect pace wise. Deliberated about just getting rid but decided to soldier on and with the help and advice on this forum im making good progress. A few of the known issues were: Really weird beeping noise while driving, usually above 30mph Headlights looked like they had been in direct path of someone who smoked about 60 a day Front bumper had a share of stone chips (and just as i got the car into my street) a clunk from the front drivers side. I started with the headlights, ordered a meguires headlight resto kit and got stuck in. Getting the headlights out was relatively simple but both headlight trays had some poor repairs done to them (add them to the Porsche parts list) Some standard cloudy lights Halfway (wondering if i had totally destroyed them) And done, fairly chuffed with how that turned out Replaced both headlight trays and the cams that pop the lights in / out Porsche life by Ross Elder , on Flickr Then started the tear down to get the turbos out Dealing with crusty nuts, started off with finesse, ended up with a huge chisel Bought a short shift kit from Alex on this very forum Finally got the turbos off, the drivers side one was in 2 pieces, absolutely destroyed. Turbo rebuild chap asked me if id like billet compressor wheels, figured why not He was having a real issue sourcing a new wastegate flap, being the resourceful and knowledgable chap he is he noticed that one from a K04 engined VAG car was the right size but the arms was too long One trip to the machine shop later and everything fitted perfectly

Next up was the turbo sumps. The sump plugs clearly hadnt been used in the near past and they were absolutely solid. I had to drill straight through them to get the inside bolt out to get them off of the turbo. I priced up new ones but aside from the sump plugs these were fine so i went about saving them. Did my best to level off my pillar drill Bought a set of milling bits from ebay Made sure the sumps were also level And got torn in It turned out way better than i thought it would and i didnt lose any digits in the process Ive made really good friends with the parts chap at Aberdeen Porsche Got a design tek exhaust for it from design 911 And some forge actuators as the ones were on it resembled dust Also received an alternator belt and a full set of coil packs and plugs After my success with the 'milling' i figured id better clean the sumps out so once the missus was out of the house i used the parts washer that she sometimes puts dishes in Cleaned up well Id had to cut the fittings off the lines in and out of these so figured id convert the sumps to accept -6AN fittings, ordered some from torques and when i fitted them into the sumps there was a slight issue My mate gus is a demon with a lathe so he scaled the ends down a bit With a wee bit of facing off and a dowty washer everything was looking lovely I then drilled out and tapped the sump plug home to accept a magnetic sump plug Porsche life by Ross Elder , on Flickr And put the whole thing together after a wash, should hopefully do the job Porsche life by Ross Elder , on Flickr

Bringing us bang up to date (i think), i have the pictures of how my turbo rebuild is going on Cores all built up Porsche life by Ross Elder , on Flickr Ultrasonic bath for the compressor housing More porsche by Ross Elder , on Flickr One complete More porsche by Ross Elder , on Flickr More porsche by Ross Elder , on Flickr According to Mr Turbo they will both be done today so i should hopefully get them back to me by the end of the week.

Howdoo man, keep forgetting you have this. Must be itching to get out in it after all this work.

What a LEGEN! :worship: Great stuff :thumb:

Haha, me too! And yes im very keen, it better be good!

Top job, looks like you are having a lot of fun. MC

I really enjoy threads like this. All the stuff I cannot do, but still like to see.

Great work! Looking forward to how the drive is after the changes.

Got to love a black turbo 8) Nice work, keep the pictures of your progress coming :thumbs:

Quite the recommissioning job! Will be driving great afterwards, however!

Those billets will make a potential difference, are you getting a map?

Great thread and great work - enjoyed that and looks like it's coming along nicely. Please keep the updates and pictures coming All the Best :thumb:

Thanks for the words of encouragement, much appreciated! Yes I'm hoping, from what I hear a good map transforms the car to what it should have been. As for who the map will come from, I'm unsure. I'm up in Scotland so I'm open to suggestions

Some great work going on there. Excellent. 8) Not sure how far away he is, or if he even does 996Ts but Stu Patterson at SP Autobahn is a whizz with the old aircooled turbos. Worth a call maybe.