Ella drives again!

It's been a little over seven years...

Cylinder Heads and Camshaft Housings Installed

A few more steps to completion.

Heads Installed, Left Camshaft Housing Test Fit

Heads Installed, Left Camshaft Housing Test Fit

Camshaft Housings Installed, Knock Sensors Installed

After a great deal of agony over the choices, I used Threebond 1184 for sealing the camshaft housings to the cylinder heads.  Fingers crossed I did it well!

On the knock bridge and knock bridge sensor, I used a bit of purple Loctite with the appropriate primer.  Apparently the aluminum hole and plated steel fastener may not be enough to "cure" the Loctite.  Given the engine's heat and the temperatur profile of the Loctite, I am somewhat skeptical that this will do much, but I figured it wouldn't hurt much either.

P&C's Installed

Noting a little milestone along the way...pistons and cylinders installed.

Little sections of PVC pipe work great if you don't have enough spare sockets to hold the cylinders in place.  I used left-over 3/4" schedule 40 from the clean room construction, but a smaller diameter would probably be a bit better.

Engine reconstruction commences!

Family heads out, wrenching commences

With the family off to the grandparents' for the weekend (thanks everyone!), I set about beginning engine reconstruction.  However, before that could begin, I needed to finish building my "clean room".  I thought about just reserving the garage for engine building, but given my rate of progress, that didn't seem like a good idea.

The clean room complete

It has AC!

Ready to begin

A ding in the cylinder-head mating surface - the next bump in the road. But this piston looks good!

Piston when first disassembled

SAI Pump Wire Insulation

A known weakness, the insulation falls of the wires leading to the SAI pump.  I addressed it by knocking off the old insulation and replacing it with Ancor marine-grade shrink wrap (1/4").  Not only did this shrink wrap seem extra sturdy, but it shrinks to 1/3 it's original diameter.  This allows it to clear the collar on the plug and still shrink tight around the wire.  But next time, I would probably just replace the wires.

Engine Pad Replacement

Out with the old

As is common, my 993's engine pad was in sad shape.  There is no easier time to replace it than when the engine is out...

The Fan/Fan Housing Saga

Broken Blade Tip

At the beginning of my top-end rebuild, I was excited about the opportunity to refinish my decrepit-looking 911 engine cooling fan and housing.  Once they were removed, however, I realized they were both damaged beyond repair.

The Damage

The fan was missing two blade tips, and the fan housing was cracked around the alternator mount.  So I decided to bite the bullet and order both new.  I figured it would at least be easy, but Porsche had something else in store for me...

Porsche 993 Top-End Machine Shop Work

Return Shipment

I am way behind on updating the blog. I shipped the cylinder heads for valve-guide replacements almost three months ago, and they came back the day before my daughter was born (the original deadline for finishing the project - oh well).

Plastic Repair

Recent progress on Ella has been slow, as usual, but I figure if it hasn't come to a complete halt, then everything is ok ;-).

The top-end machine work is done and should be shipped back from Rennsport Systems next week.  They also are doing a distributor rebuild for me.

I also shipped out my mufflers for a Fister Stage 3 conversion and ceramic coat -- I can't wait to see how they look and even more how they sound!

That stuff will all be back before I am ready to start re-assembly -- the list of "while I'm in there" tasks to do is still long.  One item on that list was repairing a cracked plastic wheel liner and a broken under-body tray.

The under-body tray (Porsche part number 99350412900) was functional and out of sight, so I couldn't justify the $300 to replace it.  However, I also didn't like it being broken.  Last year I fixed my kids' plastic slide using fiberglass tape and plastic epoxy, and I figured the same would work on this part.  Here are a few before and after photos.

Maximum Dis-assembly?

I hope so!  Ella's engine has been torn down to the crankcase, so if much more is done that means a complete engine rebuild.

Here are a few photos to commemorate the occasion.

993 Engine Photos

Having some fun with the camera...

Porsche 993 AC Belt Size

Properly sizing the AC belt on the 993 seems to be problematic.  I have tried two belts, one of which was barely long enough and the other was impossible to make fit.  I think the problem is two-fold.  First, I think the Porsche spec calls for a belt that is a little too short.  Second, some vendors sell a belt as compatible for this application, but it has a different tooth design and will not fit.

993 Engine Drop: It's Out!

Where'd my engine go?

Ella's engine is out!  It actually came out about three weeks ago, but I'd rather be wrenching than blogging :-).

The process is well documented on pcarworkshop.com and the rennlist 993 forum, and I also purchased the Bentley 993 manual. With those sources already available, I don't have much to add to the technical instructions, but click past the break for some notes on moving the engine around in a home garage and, of course, some photos.

993 Engine Drop: Prework

After reading others' experiences, I realized I would have to upgrade my 993 jacking and jack stand procedure for the engine drop.  The engine drop requires a lot of clearance at the rear!


Click for more photos and my lifting procedure.

Porsche Hood Crest

A quick and simple little project - replacing the hood crest with a custom colored one from "intrepidagent" on rennlist.

The Original Crest.
  It's in good shape, but it's the only gold color on the entire car.

FD Motorsport SSK and Goldenrod Install

FDM Goldenrod

Over the Easter weekend, a friend and I installed the FD Motorsports Goldenrod and SSK.  Despite having read many glowing reviews, I was somewhat skeptical that the setup would live-up to the hype.

Wheel Refinishing

Wheels have been Ella's weakest link ever since I purchased her.  The original equipment 17" wheels were, in my opinion, too small for the 993's wheel arches and their finish was also in poor shape.  Almost immediately, I began searching for replacements.  In January 2013, I bought a used set off eBay.  While the size and style were perfect, the wheels were beat-up.

Click past the break to see the before and after photos.

Key Fob Replacement

Skiing, business trips and a baby made for a very busy winter season and left little time for Ella, but I still managed to squeeze in a little "project" - replacing the key fob and key head.  My excuses were crack in the key fob and a key-head light that didn't work.

Part numbers, pricing and photos after the break.

DFW 993 Meet - January 2014

A simple request to hear some modified 993 exhausts led to quite a 993 meet in Dallas this January...and I missed it.  Fortunately my sister and brother-in-law drove Ella over took some photos for me.

The whole story can be found in this Rennlist post:  http://forums.rennlist.com/rennforums/993-forum/785079-looking-for-fister-users-in-dallas-north-dallas-area.html, but here's the short summary:

1. Dallas rennlist forum member rsabeebe wants to hear some exhaust setups
2. Area 993 enthusiasts get excited and join-in...nearly 30 of us
3. A raffle gets started
4. An ice storm covers North Texas, event gets postponed
5. New date selected when I'm out of town :-(, but at least now Darin from FD Motorsports can fly in.
6. More that 30 993's show up at RAC in Addison

Click past the break for some photos.

Photoshoot, July 2013

It took an ice storm in December for me to get time to process photos taken in July, but that's what happens when a future Porsche driver is added to the family...

One of My Favorite Ella Pictures

Click past the jump for additional shots.