2001 Porsche 996 LS1 Conversion Thread by 1dirtyZ

9 minute(s) of a 536 minute read

a bit of progress today , and a minor setback 

first off the setback : found out i have the whole pass side e-brake assembly missing. the only thing there is the the cable and the upper brake shoe :

i also could not get the stupid axle ( from the auto transmission) off the spindle , guess the splines were pretty rusted in there , so it was off with the spindle!

on the other hand i finally seperated the wires i need from the engine compartment :

and i think i should repaint the calipers since they are off now , (well the rears at least ) and they are rather faded .

thats it for now , i have to finish up the mounts between the trans and the engine and then i should be done with the hanging the engine .

after that i guess it would be time to start fabbing the exhaust and messing with the accesory drive.

05.28.10

Nothing much to report , 

i'm just waiting for the next batch of parts to show up. i ordered a magnaflow muffler PN12469 with dual inlets and outlets , the muffler is kind of an "x" design inside but without the pipes actually opening into each other . this would be the muffler that sits infront of the balancer where the original stock muffler used to be.

another thing i ordered is a couple of mufflers from extreme mufflers , these are "U" mufflers that have both inlet and exit on the same side. 

http://www.extrememufflers.com/index...p_image&pID=54'

these mufflers will be on both sides of the engine and will flow into the "x" muffler.

also ordered an engine harness, and drive shaft for the tranny, coolant expansion tank , exhaust flex coupler, as well as the missing brake caliper and emergency brake parts. and i should get the exhaust flanges from the machine shop tomorow .

the oil pan has been shipped as well 

untill then , i guess all i can do is cut the brace and start routing some wires and hoses.

05.30.10

Here a couple of cell pics ( sorry for the quality ) of what i did last night :

will get better ones soon 

on a side note , found out that a stock F-body alternator will not work with an ls3 alternator mount.

06.14.10

sorry for the lack of updates , but i've been busy andout or town , plus i've been waiting for the batch of parts i ordered to show up. 

here's what i did so far:

i cut the brace and welded patch panels to close the holes , i also found out that the muffler i ordered (magnaflow p/n 12469 ) is not the design i was thinking it was : apparently it was dual inlets aand outlets that merged in the center of the muffler , i was hoping that it would be two seperate paths that crossed in an x pattern but did not open up on each other.

any how here are some of the parts that already showed up :

and here is the ultra sexy kevko oil pan and integrated baffeling :

EVOms GT2 clutch hydraulics conversion :

and here is how the brace looks like after cutting and welding the patches:

ike i said i'm still waiting on some parts to show up like the harness and extreme racing mufflers and the GT2 solid bumper braces so i can begin fabbing up the exhaust and brace reinforcement and the rest of the brake parts . i'm also am waiting for the driveshaft to show up along with some other things here and there 

so as for now , all i can do is build up the mid mounts ( between the engine and trans - to help support the two just like a mid plate) as well as route a few hoses here and there. after that i should start thinking of where and how to route the LS1 wiring harness and clean up the existing wiring in the engine compartment.

06.23.10

time for some updates,

been waiting for parts to show up, and most of them are here now; 

the wiring harness from ls1wiring.com is here

and so is the 360 deg. swivle thermostat housing ( i was hoping it would be smaller than that , but oh well,,, ) 

the front driveshaft also showed up , and it seems i have to shorten it by 3 to 4 inches!

here you can see how the kevko pan fits , and how much clearance that got me :

and since i had some time on my hands while waiting , i decided to make something ,,,,,, you guessed it ! MORE ENGINE MOUNTS! 

the thinking behind these mid mounts was that the front plate provides side to side bracing as well as lifting the front of the engine, while the trans mount kinda provied front to back bracing ( i say kinda cause its a huge floppy rubber donut mount), so i thought adding a bolt-in mid mount would not hurt anything and would provide front to back bracing ( helping to prevent the mounts on the face of the engine from bending ).

i started off with making two plates with tabs on them for the bushing , these plates would bolt to the suspension cross member on both sides:

i then started building the part that connects the plates to the block , it just a simple tube with a bushing on one end and a plate that bolts to the block on the other :

i like welding stuff 

this is how it looks when done on the driver's side:

and on the pass. side :

and how it looks from under the car :

and here is a shot showing both front and mid mount :

so i guess i can scratch building the mounts off the list now 

there are a few more parts on the way ( brakes and "U" mufflers ) that have to be here before i can continue , as well as some other assorted thingies here and there.

so when those show up i will start on the other things on the list :

- start fabbing the exhaust system 

- finish bolting up the brakes and e-brake 

- build the cradle that will be used to lift the engine/trans in place 

- finish plumbing the clutch hydraulics 

- start working on the coolant lines

- probably make some more engine mounts

07.06.10

major mile stone acheived last night !!!!

i caught the martha foaking rat in my garage !

(i actually caugth two but this $hit ate the other one - all of it except the head and tail end ! )

other than that some parts showed up but not all of them. got the caliper , most of the ebrake parts , puke tank, sway bar links , and hood struts in today , but the whole brake thing is on hold till i get one itty bitty part 

i'm almost done with the engine cradle that will be used to move the engine and trans in place :

also finished mounting the GT2 solid bumper mounts , making the rear bumper a stuctural peice :

mufflers should be here any day now , so when they show up i can start with the exhaust system.

i probably will start routing the coolant hoses for now untill i get some more goodies in .