Build is Almost Done, Maybe 2 Weeks Left 993 Turbo by carmstrongLS1

29 minute(s) of a 61 minute read

Build is Almost Done, Maybe 2 Weeks Left 993 Turbo

Compliments of carmstrongLS1 @ www.6speedonline.com

2/1/2012

Maybe two weeks and she will be home!

The design on these are supposedly a similar design to the 993/996 GT1. Different from the "run of the mill" Billet K16's around. I hope you guys approve. This forum has been a bit quiet lately. Not many peopl interested in our oldies but goodies it seems. 

evo cams as well. This was the final pieces. Pistons, cams, and jugs weren't on this invoice. 

I chose to stay 3.6, Todd seems to think we are still going to get a monster out of it. He specifically said... "I shot for 600 whp. That's what we will get" 

2/5/2012

I hope its fun. I cannot stress how bipolar the wait process has been. Which was not fun. I am packing up a bag of my tools and heading to motorwerks on Monday to see how much of a helping hand I can be personally. I built this car in memory of my father, who recently passed away from leukemia. 993 was his favorite car. He had several 993 cars including a red 97 TTS. I found the exact car he owned in Colorado. They wouldn't sell. So I did what I always tried to talk him into... Build a monster, but he was a purist. I remember callingTodd K. When I was 11-12 years old. Asking about prices and what could be done. Printing it out and tryin to convince my dad to have it done. He never would. So for the purist factor I have a bonestock red 996 with super low mileage. Then this car which is strictly a dream come true for my family. 

2/9/2012

A few pics. Still uploading them now. 

Cams and what not. Just found the seals and gaskets so I believe the motor will go back together starting next wednesday. 

and more on the way.

the Misses got a little something out of the build too 

Some tools to take care of the baby. I am going to start doing little things it needs.

They are K-16 based hybrids but the 16G side is more similar to the 993/996 GT1 race dimensions. Thats about all I know. Its not the run of the mill K16/16G.

I believe UMW also makes a hybrid very similar. 

and this for the Jewelry that I will most likely have to buy to make up for this build chaos. I have two projects going at the same time so she really has been a good sport. The old school truck I am building has proved to be time consuming for me. I have done everything with the exception of body work.

Yes, actually he said it will be 600 whp. Todd said the same. I will PM you. 

2/12/2012

I forgot about these. 

2/21/2012

After Cases were cleaned 

 I was going to media blast and clean these but circumstances did not permit me picking up the parts to polish from Motorwerks. That would have been pretty sick to have a nearly  motor though. oh well I will save that for the truck.

Before...  

This is pretty disgusting.

2/22/2012

This is so good looking it is going to start its own thread 

I am pleasantly reminded why I love B&B exhaust so much. These welds and tips are to die for.

cam boxes 

more clean stuff 

2/27/2012

getting reassembled 

here we go guys. A little at a time.

3/1/2012

Case assembly 

I guess two weeks was an incorrect estimate.

3/12/2012

since I stayed 3.6 the Pistons were a tad bit narrow underside. Pauter machine is currently going to pocket out forrod clearance and send back... Stupid delays. 

3/19/2012

Piston skirts 

So the parts are back and the build resumes. I bought a new Ecoboost F-150 SuperCrew to tug the toys around. Should be good. All the stereo equipment and what not out of my Honda is going in it. Ecoboost is probably the best thing to come from america since the LS engines. Only time will truly tell though.

4/11/2012

finally coming together again 

Had a small time consuming issue. There had to be about .0625" pockets ground out of the inside piston skirts. Since I stayed 3.6 the Pauter rods were a little large for the rotation. Something I guess uncommon since most of these builds go 3.8. Then the situation is a nonevent since the inside diameter on the 3.8 piston is slightly larger. Well here is a picture of the last phase before the heads get put back on.

4/24/2012

more good stuff for your eyes guys! 

A few pics of the last phases. I sent alot of parts from the engine bay out to be high temp coated red like the brakes. The alternator fan as well as the intercooler cover to be the "Big Red" Just little touches to set it off. Maybe see a bit of color through the whale tail.

and... 

different angles

main goal here... 

I want to be quicker than a C6 Zo6. Thoughts, ideas, questions, comments?

4/25/2012

Well... Next year is next phase. I will do headers, bigger turbos, and intercoolers. I won't get much time to enjoy this phase now. Off to work in China for a few months soon. 

4/28/2012

Tial Turbos 

Akram tells me we should try Tial are up for the next phase. So up next year is a nice Fat Proto Intercooler, Custom made exhaust manifolds and a few other goodies. As of thursday we began preperation on thursday by picking a clutchmasters carbon/kevlar unit. So... Once again, here we go. To think I haven't even finished stage 1 and we are starting stage 2. 

5/2/2012

updated today 

5/7/2012

ho hum... This part of the build is wearing me out... 

Al, I need some advice on a clutch, What are you running. Seems to have all of the clutch tuners running for a loop when we say 993. 

This time wasting, nickel and diming, last stage and we need a good clutch.

I spoke with the guys at andial today. Gave them a peek at the build sheet in the beginning of the post, They said the only thing they had was a track car setup that would suffice. That setup he said was not streetable.

5/9/2012

I spoke with Todd, he sourced everything and its on the way. He said we are going to go with an RSR Lightweight flywheel and a sachs 764 997.2 GT2 RS disc/slave setup. Right now he has it in a few cars that are recent builds. Just like you said it is a hybrid build of matching dimensionally porsche parts. They do after all... Build race cars  This setup is currently holding 970 wtq in one of his cars that he built this year

New news is that we are going to replace all the brakes and the entire steering rack assembly. The crappy part is that the seals aren't available separately. Being that I am now in the oil and gas industry I think I will try to source cross referenced parts and attempt to rebuild it on the side to see if I can have a spare or get it good to pass on to a needy person. 

One thing after another but I put a cap on this project today for this year. Gotta get this thing on the road sooner that later. 

Next year though... BIG POWER!!!!!!!!!! TEXAS MILE!!!!!!!!! TEXAS HALF MILE!!!!!!!! I need it in my life 

5/19/2012

clutch on the motor, new brakes all the way round, modified heater piped ducting and relocated 02 sensors. Got some brackets fabb'd up for the ducts to go back into the and... Friday of next week we start putting some miles on it. 

Here are some pics 

a few they emailed me.

5/24/2012

progress 

The fabspeed is only here for some fitment testing. B&B goes on last they said. Man it sure is coming along nicely, But please guys... Disregard that exhaust. Ugly as sin. 

I am going to polish it back to a mirror finish at my shop. And I have some good spare parts for sale. 

SACHS clutch and flywheel that only had 2K mi. on the, Good condition connecting rods, The fabspeed bypass... That will look brand new in a week or so. Working in a massive machine shop has its perks  I think I can tumble or media polish anything. Automated too. Like that Ronco Rotisserie.

one or two of those pics were bad. 

They really know how to clean a car up at Motorwerks. I am very impressed.

5/30/2012

Methanol injection, Alpha 3076's, and 80# injectors up next. 

update 

car is now running, I have not driven it yet but I heard a video of it.

6/4/2012

Frustrating... I found out today that the guy finishing up the build is on vacation... So, that means I won't be seeing my car for a few more weeks. Needless to say I am NOT a happy camper right now. 

6/19/2012

update!!!! 

Update: test fitted the current setup. Then motor came back out...

GOING big power instead now.Alpha 3076 and appropriate mods. I just can't wait any longer. Even though I never drove this setup... Why wait? Questions, thoughts, comments. 

For sale are the Billet 16g turbos in the classified section.

7/12/2012

So Two weeks like the thread stated... Its turned into 24 weeks. Still not done. So 16 months into this thing... I am bored. Think I may do a renegade LS3 944. After all this proect drained from me I am afraid to break it racing. Yet... I need something to race. 

8/2/2012

It's still not done. Close but we needed to go back to the drawing boards for the piston setup. These cams were supposed to be an evo setup but in all actuality the profiles were much larger so it's more of a race cam upon checking, double checking, and quadzillion checking the dimensions and degrees. It is an alpha 3076 twin plug 3.6 with pauter rods, every surface that could or would need polydyn type coating got the treatment, custom machined pistons, force fed EDM'd (electrical discharge machined) oiling system through the con-rod beam from bearing to bearing. Still a hydraulic lifter setup for street ability and use. Everything that may need replacing in the near future is new. Te only thing we kept were the main cases, the head castings, and the exhaust manifolds. Simply for lack of good cost effective replacement. Most aftermarket header systems are less durable than the factory's investment cast pieces. 

The build time... I expected 6 months. Wrong. It takes a long time. So far it's been 16 months and still counting. Should be on the road in October or so. I am not sure. 

The budget... Well... Umm... You could go buy another pristine 993 TT or you can build a motor similar to this one for your current car. Truly just a preference deal. Two cars or one rocket. It is up to you.

I don't think I would have changed a thing. I learned a lot. Fun times chasing rare parts. Machining custom pieces. Piecing together something you absolutely will not see pull up next to you at a stoplight. It just wont happen  

Todd said it when the list was finalized, "Chris, it will be a truly amazing car." I believe him. 

9/30/2012

514 days since I have driven my car... sadness is setting in. 

11/10/2012

Update. Should be driving the car this Friday. I'm machining my self a custom profec mount this week. It should be really nice. It will replace the drivers side AC vent and still allow air to pass as well as still have the functional airflow valve. The motor was stripped down again and the job was picked up by another person. Chaos that I wish to not speak of. Unfortunately my car was involved in the middle of. When this last disassembly came about. All the fasteners were deemed ARP. Why not huh? It's only been a decade why skimp on the fasteners. 

Profec mounts will be machined from carbon fiber plate. If anyone is interested after I get a total cost I would consider group sales to 6speeders and rlisters alike. I just need to see how long the machining cycle is. That will be the greatest kicker. The billet ones will be tumble polished to a near mirror finish then clear anodized. Please note these are for the new model profec EBC units. 

More photos 

Figured you guys would enjoy seeing the supplies.

11/12/2012

Should fire up this week.

It been a long stressful road. But... Patience. I guess. Is all that has kept me sane. Probably my sobriety has helped too. Haven't drank a drop in almost three years. Can't say I would have been this patient had I not put that bottle down. 

11/22/2012

Here's the first cut prototype boost control ac vent mount. 

It's not done yet. Motor goes back in right after the holiday. 

The only thing retained OEM was the engine  case. The list is long. What I am holding back on until the break in miles and the motor coming back ou is:

Intercooler

3076 turbos

Billet upper valve covers

Carbon fiber engine shroud

Todd is also still fabricating the exhaust which will go on with the new turbochargers. I want to break the motor in on relatively low hp and stress. See how she acts. Then install the rest at first oil change. It'll be a hefty oil change. 

Todd says the combo is good for 600 whp in this modest trim. We could go for almost 700 with the methanol injection but I'm shooting for old fashioned cool air charge temps. 

Build 

Heads, cams, pistons, rods, twin ignitions, Proto DME, new billet turbos, dual oil coolers, billet lower valve covers or dual plug ignitions, 60# injectors, new valves, guides, cleaned up heads. 

Flame ringed reinforced and machined, web cams evo cams, full mechanical rocker set, upgraded valve springs from Protomotive. ARP studs and bolt throughout, pauter EDM forced oil rods, custom relief machined (.160") Mahle pistons, new bearings an seals throughout motor, all friction Bearing and heat Bearing surfaces polydyn coated. 

Carbon bits here and there, plx display machined into factory vdo tach, 2012 greddy profec, custom mount, custom exhaust (2 different setups actually), completely custom wiring harness, custom heater pipe ducting, H&R cup col over suspension complete, new brakes, new steering rack, super cool clutch and flywheel. It from a GT2 RS. With a GT3 RSR ultralight flywheel. Looks like jewelry. 

There's more I know, but hats the major. Everything has been dry ice cleaned with the motor an tranny out of the car.

11/27/2012

Cams all timed. Motor sealed up. All the little parts going on it yesterday and today. Should come to life in a couple days. Of course the holiday put a damper on the progress. 

1/19/2013

Sorry guys I've been busy. But, supposedly the car will be done very very soon. I've gotten a monster size Protomotive intercooler in there now. ARP head studs. All the valvetrain is fully mechanical as well now. The guides were replaced again, the underside was cryodetail cleanses, which I'm not happy with the contractors work. Him and I disagree. I'll bomb that one later. But if you are in the Dallas or Houston area I can tell you who not to use. 

Also I loaded the entire interior wit some carbon from Marcus Buehler. To keep it different i had him put the famous slogan in which I believe in the door sills. It's killer IMO. I guess after taking this long to get something done my opinion is all that counts lol. Jk. It's been a long road.

Pistons were machined and recoated. The exhaust is going to be straight three inch off the turbos down to 2.5 at the heater boxes. Then out the b&b bypass tips. Should be loud. Like I like it. 

Updates coming soon. 

More good stuff here

"Exclusive" option lol 

Discreetly placed

2/9/2013

sorry for the crap video. Phone upload and I was in a hurry that evening. Shes alive. The motor sounds damn good. Excuse the tach etc. Its not completely wired in yet. Nor is the interior finished or the intercooler and exhaust cat delete done yet. Looks like a week or so more but I will be in NC for a short while. Anxiously ready to get this story behind me and finish my Big Block Chevy truck build. 

2/27/2013

Well, as I sit here... 

Unfortunately I suffered a very bad lower back injury last week. I am bed ridden until further notice. Hopefully no surgery. 

This is my first back injury. Hopefully my last too. It's insane pain.

3/10/2013

Yeah. Life is getting back to normal 

Chaos. I just got back to working recently. I'll post something nive for you here. Car is coming along great. It's done mechanical wise. I have been limited to driving my F150. Next week I am going to begin driving the focus ST. Get better to stretching the legs out that many times a day. Then the 911 will hit the road.

Intercooler 

Turned out nicely

Carbon bits 

The e brake handle was an incorrect fit. I need to find an OEM unit with carbon and leather.

3/17/2013

Update 

Car has been picked up by trailer and transported to Protomotive in Arkansas. 

Still has yet to be finished. I've been holding back with my tongue but now... I can't hold back anymore. It's been 2 whole years since this thing started. The shop here in Houston failed to produce a working completed car. Incorrect assembly caused failure upon first start which was one year ago now. 

Protomotive is a great tuner. They machined everything and got the motor new again. This time it went together and started. A very experienced technician did the assembly. Protomotive did all the machining of the cylinder heads and pistons. Finally got the engine right. 

Now the car will be gone through and a complete custom fabricated X pipe exhaust with functioning heater boxes. Built in a somewhat unconventional way. Similar to the work I have seen at s car go. With stock looking exhaust tips. The B&B exhaust tips were uneven in both level and length. 

The cars interior was nearly trashed. It has been rough two years in that shop. People just treated it like an unwanted child. I noticed dents in the doors and fenders. It was rolled into whatever corner seemed to be out of the way and forgotten for months at times. Just a really bad deal. 

I tried to continue patiently waiting but sometimes... Enough is enough. Promises after promises and empty ones at that. The reason there was N issue with getting the cats to rare911s was even based on these empty promises. They kept putting it off and putting it off. Saying that the exhaust would be taken care of. Nope. Never happened. 

I hope they are ale to get their crap together. I really do. Maybe sales and oil changes should be their forte. But for now. I am not sure. They are very nice people cut unfortunately you can't keep the lights on with nice. Ou can't keep customers happy by being nice and not delivering. 

Plan is to have the car back in Texas for the April invitational. Todd will trailer it back to meet me at the event. From there I will drive it home.

3/18/2013

Back is getting better. I got back to working a full schedule last week. Though after working and coming to a rest it's a bit of pain. Trying to keep it on my mind so I don't accidentally strain it. That's the hard part. 

I trust Todd to take control. It's what he does best. Most of all though he actually cares about the clients. The outcome. As well as the long term. He has a great reputation for a great recipe. My wife is actually happy too. That's worth a Carrera GT in itself. 

Still I'm stuck with body work to get done after its all over. Crease type dents on both doors from pressure being applied against the lifts as well as a few dents here and there on the body. I guess it will be a call to the insurance company after all this. Might as well repaint the whole damn thing. Especially after seeing AMGGTRfans car. 

3/27/2013

update... Tial sport Alphas going on the car. They will arrive from Tial Tomorrow. Next week the full custom exhaust transformation will happen. One off Custom. As straight as it possibly can be while still maintaining the heater capabilities. 

The guys at Proto are the Shiz. for sure.

5/2/2013

Excuse the map pic. Just wanted to show you guys the artwork happening in Arkansas. In pretty sure this counts as a quality exhaust setup.

7/13/2013

Just some little update action... 

10/2/2013

Cam chain housing cover 

So... 14 weeks or so to get parts from Porsche to fix a cam chain housing... Not cool. The wait is over though finally. Car is getting some of the new boost hoses and all the other available hoses from S-Car-Go racing. Which I am stoked about. Then Cynthia will have her back together. Todd says lets not kludge it back together. The dang part was magnesium so we could not weld it and remachine it. Of course. 

I told Todd this I'm in the stage of a nightmare where I keep trying to run. Only to trip on my face. So it looks like Christmas time I'll go pick it up. Ho hum.

12/7/2013

Going nicely. Dyno time and minor changes here and there. They used my car for aftermarket exhaust development at Protomotive. Created production templates for a true 3" setup that anyone can order. With or without heat exchange, with or without mufflers. It looks nice. I kept the heater ditched the mufflers. It'll be pretty nasty. All is well though. 

Todd an his crew have been great. They've picked up all the pieces and put the car together very nicely. They reassembled the interior. Installed all the carbon parts. Did all the electrical wiring properly. Even took the entire engine apart to check the previous work down to the level they were comfortable with. 

All the hoses were upgraded to the S Car Go setup. The car is being dynotuned real time. It's gotten brakes, steering, mounts, alignment, a slew of high quality engine components and work. I'm happy. Not to leave out all the carbon fiber everywhere including the new steering wheel. I'm thinking my next round of goodies will be more fuel. All that jazz. But 60#ers and nice pumps will do for now with the Alpha 28's and a boat full of boost. She's tuned for MS109 and a street tune. 

While I'm not going as far as Mike has plans for. It will have some settings in the OBC that is now in the dash with help of the new profec controller to be sure of causing a good time to occurr. 

All in all she hasn't had a single mile put on her in. 3 years. So that's a good thing. 

8/16/2014

Finally... Done. I'm so happy with the results too. Pump gas tune is great. No kill mode dyno though. I'm gonna take it easy on her after all this.