2001 Porsche 996 LS1 Conversion Thread by 1dirtyZ

9 minute(s) of a 536 minute read

got the oil cooler/fan assembly in , this will most likely be fitted on the decklid :

the mufflers also finally showed up from extreme mufflers , and man do i like'em !

as you can see they are two "U" mufflers and two bullets , they are both as free flowing as they get and the plan is to use one of each on each side.

the headers will face backwards and i will not use the stupid stock flange on them , i'm going to port the lip on the original flange cause its only 2.5 inches in diameter ( seen here :

and will weld a small extension with a 45 deg. angle on it ending with a ball flange , i was going to go with flanges but using ball flanges offeres better fittment and is more flexible when it comes to pipe missalignment . after the ball flange there will be a U back into the muffler then the gases make another u turn and exit the muffler into the bullet muffler and the exhaust tip. here is approximatly how the mufflers will be placed :

and the extension and ball flanges that will be welded on to the headers :

and here's a weird occurence , as soon as i finished cutting the metal donuts to make the 180 turns the pipe split at the seam :

but that wasnothing that the TIG welder couldn't fix 

the oil cooler lines , remote filter and fittings should be here very soon as well as the rest of the brake parts , so finishing up the bottom side of the car should be happening soon 

so the plan tomorow is to:

- port out the header flange so i can weld on the 3 inch ball flange.

- weld the rest of the exhaust and figure out where to mount the hangers 

- put bait on the mouse trap to catch the other martha forking rat that i saw today 

- i might just lay the harness in the compartment and see where i'll route it into the car.

- clean the mess i made over the last few weeks 

07.13.10

on with the build , i got some oil filter fittings in today as well as the remote oil filter housing , fuel filter and lines as well as fuel line fittings .

i didn't get much done today cause i got there late , but i did manage to weld the 45 deg extensions on the headers :

and finished welding both 180 deg bends to the ball flanges :

and yes ,,,, i did bait the trap

07.15.10

i'm almost done with the exhaust now 

here is how the final product looks:

and this is how it looks on the car :

and here is how it looks from behind :

i still have to finish one more weld and place a couple of tabs and both muffler assemblies will be done . 

next up is figuring out where to place hangars and getting some porsche tips, then later put some heat shields on them for some added comfort .

next up on the to do list is to finish the brakes , coolant lines and i should be mostly done with the bottom side of the car.

07.18.10

i guess i can say i acheived one of the milestones of this project; i am completly done with the exhaust. ( well,,, i still have to do the tips )

i finished welding the last muffler and hangers , and to tell you the truth i'm impressed with what i did 

rear view :

and a side view ( i actually have more clearancce than stock ! )

i also started thinking of where to mount the cooler and oil filter . and after many minutes of head scratching and staring at the engine compartment i came up with this location :

and the oil cooler will be next to it and stretch across the bumper. i also plan on using some quick disconnect fittings from the oil pan to the oil filter for ease of removal .

07.19.10

so now its on to other things 

i still have to measure how much the driveshaft needs to be shortened , and i really need to work on the hoses under the car which includes clutch ,fuel , coolant, heater , and p/s lines.

any how , according to my list the next thing to do is :

- measure and cut driveshaft 

- oil lines, filter, and cooler

- finish routing the hydraulic lines for the clutch 

- start on the fule line stuff 

- i guess i will delay the harness for a bit , i want to do all the electrical work at once.

- install some heat shields around the mufflers 

should keep me busy for a while

08.11.10

i finally have the rear brakes done , all i have to do now is bleed them and later down the road paint them and add the "porsche " stencil to them :

gotta love the rusty rotors

i also figured out where to mount the oil cooler :

i also had to clerance the oil filter pad to clear the belt :

here you can see how close the belt would run by the oil filter:

i also found these cool hose seperators from summit , nice and clean :

also got the puke tank and vette filter/regulator mounted in place :

and here are all the fittings on the filter :

all i have to do for the fuel system is run a hose to the fuel rail and attatch the return line and that should be it for the fuel system .

also looked at the cooling system plumbing ; for the heater hoses i'll be using an ( of all things ) f-body heater hose assembly wich fits and tucks in real nice under the puke tank and connects to the stock porsche stuff . and on one of the hoses i have to T in the puke tank itself just like on vette cooling system. all that is left to do for finishing that is a couple of under car soild lines i ordered to show up.

as for the rest of the cooling plumbing , i decided to just get some stainless steel pipes and elbows and make my own coolant lines after messing with countless rubber hoses, this way i guarantee myself a better fit and one less thing to go wrong in the long run.

so next up on the list is finishing the fuel lines , fab up some heat shields to seperate the headers and mufflers from what ever will be above them as well as isulate the cooler lines, alt. and A/C compressor where they get real close to the exhaust .

i'll also see if i can the heater hose done as much as i can without the parts i ordered .