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.

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.

Porsche Photography Class

Our local PCA chapter hosted a fun and educational photography class last month.  A big thanks to Charlie for running the class and to Park Place Porsche for hosting the event.

For me, the highlight of the class was the live photo contest.  Here were the contest constraints:

• 45 min to shoot in the Park Place Porsche parking garage
• Photos must the interaction of people and cars (in keeping with PCA goals)
• 15 min to choose your single favorite photo

The contest presented a number of challenges.  We were shooting mid-day on a Texas summer day -- harsh sunlight!  Inside the parking deck, this meant very bright light at the periphery with low light on the cars.  It was also a bit challenging trying to figure out how to work people into the photos as we were all busy trying to shoot.  The photos entered in the "contest" can been seen on the Maverick PCA website here:  http://mavpca.org/photos/MRPhotoGallery/Technical%20Events/Tech%20Seminars/2014/index.html

Thanks to a generous interpretation of "people", my photo won second place!  Click past the break for the prize winning photo.

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.

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.

A "Racing" Helmet

My six-month old unfortunately developed a woefully lopsided head (positional plagiocephaly) and the doctor prescribed a head molding helmet, aka DOC band.  Given the price of this piece of plastic, it only made sense to adorn it with Porsche logos. ;-)

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.

Porsche 993 AC Compressor Replacement

As mentioned in this previous post, Ella's AC compressor was suspected of leaking r-134a refrigerant and needed to be replaced.  The repair quote from the mechanic was absolutely ridiculous, so I felt free to buy tools and equipment as well as the parts. :-D

For an excellent how-to article, check-out http://www.pcarworkshop.com/index.php/993_-_A/C_Evaporator_Replace.  Although the title says "evaporator" replace, it also covers the compressor and the receiver/dryer.  Rather than re-create the DIY here, I made a few small contributions to the article on pcarworkshop. Ella even makes a cameo appearance!

In this post, I will cover some of the special circumstances and considerations from my install.

Porsche 993 AC Bracket Repair

Broken Piece of Porsche 993 AC Compressor Bracket

As I was lifting the AC compressor off its base, I heard something metallic falling into the engine bay.  My first thought was that I had missed a bolt or nut somewhere, but I was very careful about that. I looked down into the engine bay to find a piece of the AC compressor bracket.

You could see from the changes in color along the break that it had been cracked for sometime.  I also know of one other 993 owner who experienced the same issue.

Grounded!

As summer heated up here in Texas, Ella's AC seemed to be growing weaker.  After one miserable hour driving around Dallas in the summer heat without effective AC, I took her in to the shop.

The Culprit?

The mechanic noted the refrigerant was almost completely depleted, but couldn't find the source of the leak.  He added dye and refrigerant and told me to return if I noticed poor AC performance.  A few weeks later, it was time to head back to the mechanic.

This time, he diagnosed the problem as a leaking seal on the AC compressor.  No problem, except that it would cost $2000 to repair with $1500 in parts alone.  After a quick look at the DIY instructions and a search for parts prices indicating I could get the parts myself for $300-$400, I decided to tackle it myself...

It seems that maybe I got myself into a bit more than I first realized, but that story is for another post. :-)

Porsche 993 Fog Light Reconditioning

Ella's fog lights needed some reconditioning.  The passenger side fog light had been cracked by a large stone, and was very yellow.  The driver side looked much newer -- like it had been replaced once already (hmm...don't remember that in the car's history, oh well...).

Porsche 993 Headlight Overhaul (or Ella's New Glasses)

Ella's headlights were looking a bit tired from the rock chips to the yellow-hued bulbs to the yellowed headlight lenses.  She was ready for a makeover.

Replacing Porsche 993 Third Brake Light Bulbs with LEDs

When I purchased Ella, she was sporting a gap-toothed look on the 3rd (middle, high mounted) brake light.  This is really no surprise as the design uses 24 (yes, you read that right, 24) individual incandescent bulbs.

A quick search on rennlist revealed several others had the same thought I did: replace the incandescent bulbs with LEDs.  Even better, several options had already been tried and validated.  I just followed their lead.  Read on for the details and lessons-learned in my install.

[Update 12-Feb-2016]  I recently noticed that Tore at Bergvill FX is selling a kit to replace these incandescent bulbs with LEDs.  While I haven't tried this specific product, my experience with Tore has been great on other products, and I would use his kit if I was to do this job again.

Ella's 5-year PIP (Porsche Improvement Plan ;-))

My back log of projects is nearly complete, so I started day dreaming of where to go next.  Based off a list I put together a while back, here's my "plan" for the next five years.  The only thing that is certain is that this project that won't go according to plan.  Have suggestions; please leave them in the comments below.

"Temporary" Rock Guard Replacement for My 993

The clear rock guards on my 993 are in pretty sad shape.  On both sides, chunks are missing and multiple rock hits have gone all the way down to the paint.  They are also anything but "clear" or "paint colored".

I have been wondering if re-doing them in black would lend a nice retro look, and I found the perfect way to give it a trial:  magnetic rock guards from MagnaGrafik (thanks to Bruce7 on rennlist for the pattern)..

I installed them over the existing stone guards so that I can go back anytime.  Someday I hope to get the paint fixed, but until then this is a very budget friendly way to improve Ella's appearance.  These looks so nice, we may even play with some additional magnetic decals :-).

Before                                               After

Porsche 993 Online Media Catalog

A simple list of links to my favorite online Porsche 993 media.  I will add to it as I go. Enjoy!

Articles

A sentimental story from Road&Track:  http://www.roadandtrack.com/features/magazine/features-magazine-features-breaking-promises-jack-baruth-porsche-911

Buyer's Guide from Car&Driver:  http://blog.caranddriver.com/1995-98-porsche-911-carrera-buyers-guide-econo-exotics/

Videos

Patrick Stewart narrating a Porsche Production

Porsche 993 - An Owners Perspective

Chris Harris's Review of the Singer 911

If you aren't familiar with the Singer 911, do NOT watch this video...you are better off ignorant ;-).

Blogs and Personal Websites

Jackal's Forge

Photos

Porsche's 50 Years of 911 Photo Stream:  http://50years.porsche.com/

How to Install a Strut Tower Brace in a Porsche 993 (and drill-out a broken strut stud!)

Installing a strut tower brace in Porsche 993 is really pretty simple, but I still managed to make it take forever.  The  brace discussed in this post is a TechArt model I bought used.  The seller shipped it with absolutely fantastic packaging -- I've received new items with less professional packing.

Read on for a few notes on the install.