21st Century Outlaw 997 Project

[Darren C]

“We looked at it and quoted him £28k to sort all the issues out”

That was a…..SNAP, and you’re back in the room, moment.

“Okay, what price for just the liner inserts?”
“£5K if we take the engine out, but it WILL need more”
“What it I just send you the block & you line it?”
“£3K”

So, thus began the 997 3.8 engine rebuild…..
Pictures for Mike

Once out it was foolish not to break it down into all its individual components for assessment

With engine in pieces a list of parts was made.

This included:
Bearings
Chains & tensioners
Followers
Oil pump
Waterpump & new hoses front to back
Set of new pistons & rings
IMS bearing upgrade
New Starter Motor
6 coil packs
Missing heat shields
New engine wiring loom (only £200 while engine was out and a known Gremlin fault on 997)
Refurbish existing cylinderheads
New Eurocup full-flow Stainless Sports Exhaust system (original was ok, bit rusty, but hell, in for a penny in for a £)
All seals & gaskets plus a few nuts & bolts
And some other stuff I can’t remember

This was going to be about £5K in parts but I would end up with a fully rebuilt 3.8 while Porsche, who stopped selling “short blocks” for the 997 at £11K last year, wanted £17K for a base engine without ancillaries or sports exhaust.

Yep I’d talked myself into this still being a good idea!

[keith fellowes]

This is great, well for those of us reading it! I bet at the time you were ruing your impetuosity!
Is it compulsory on this forum to be slightly, err, off piste? What with people going to Marseille to buy cars they have never seen?
Looking forward to the next instalment

[Bootsy]

Is it compulsory on this forum to be slightly, err, off piste? What with people going to Marseille to buy cars they have never seen?

Got to keep up the ‘Maverick’ moniker someway now we are all getting a bit older!

[Darren C]

With the engine stripped all components were OCD cleaned, including the Block prior to sending away for machining to accept liners.

The liner wear speaks for itself

And corresponding piston wear causing slap

[jtparr]

Never thought I would enjoy reading about a water boiling modern......
Looking forward to this......

[Darren C]

Welcome to the Darkside

Anyways, to continue...

With the blocks back from machining with nice new liners and all the parts acquired it was time to re assemble from empty crankcase upwards

Then fit the blocks. The dark colour liner inserts can be clearly seen in picture with nice new pistons (pen marked for correct orientation)

And while the engine was out I set about an OCD clean of the engine bay. Particular 997 faults are rusty brake pipes that run over the top of engine gearbox, leaky water pipe seals & wiring loom. All these got attended too, replaced & plenty of waxoil protection afterwards

[Darren C]

With the cleaned & tidy engine bay my attention continued to all the suspension & stuff underbody stuff you can't get to when the drivetrains back in.

Everything got a good going over while I awaited delivery of the Full Flow Eurocup Stainless Sports exhaust.

Unfortunately, when it arrived, like most aftermarket Porsche stuff the fit was terrible In fact the cross-over pipes obscured the O2 sensor holes, no matter how much I tried to manipulate it, I ended up cutting and re-welding the O2 sockets further down the pipe.

[map]

Fascinating project and am interested to see the photo of the cases/liners - I thought the consensus seemed to be for closed deck liners and these look like open deck type.

It is possible, actually it's likely, I've misinterpreted the photo - what type of liner did you go for? Would be interested to know why if you're happy sharing that.

[Darren C]

https://www.youtube.com/watch?v=twEFVRoe0jA

[sladey]

Great thread! - keep it coming

[MikeB]

Cracker, keep it coming

[andytat]

Loving this! I quite fancy a project 997 myself.

Andy

[Darren C]

With the O2 sensors relocated in the Exhaust...

The engine, now highly detailed with equally clean & detailed gearbox went back in...

But before I dare drive it again it was time to sort out the brakes

So first job was to pressure wash it off under the arches.

[Darren C]

The brakes were in a sorry state

So it was new discs all round, but as always I wanted to repaint them inside the vents & outside with heat resistant paint to slow the corrosion down this time around

Work continued with:

Caliper removal & home refurb
All New Brake hoses & clips
New Pads
New handbrake shoes & clips
Followed by a full detail, clean paint & remove/replace all fittings under each arch including suspension for a nice refresh

[Darren C]

And the other 3