A Star in the Making

[txhokie4life]

Here is my ongoing photo essay of my project to resurrect a 2000 Boxster S.

I purchased "Star" over the summer with the initial plan to turn it electric.

But the electrification was going to be way too expensive -- so I turned to rebuilding

the engine. We hope to have it back on the road in the next few weeks.....

If you like engine tear downs and rebuilds -- I hope you find these pictures interesting.

Also includes photos of the improved IMS from LnEngineering.

I have to thank Jeff at Sunset for the tons of discounted parts and ease of ordering.

A Star in the Making

enjoy,

Mike

[RFM]

Nice , txhokie4life well done. I hope you have enjoyed it.

[Rising_Sun]

Great photos and very interesting to see, make sure you post a movie clip of the start up. Looks like a clean motor apart from the water pump catastrophie, moral is - when the dash lights up like a Christmas tree - STOP!

[phillipj]

Great pictures and comments. Thanks for the detailed commentary as well. Please keep us updated on the final install!

[phillipj]

Great photos and very interesting to see, make sure you post a movie clip of the start up. Looks like a clean motor apart from the water pump catastrophie, moral is - when the dash lights up like a Christmas tree - STOP!

I never got any CEL or any other warning before my engine failed. Although my water pump shaft didn't shear off it was the cause of the failure. Got no CEL or overheating warning. I wish I would have :huh:

[jmatta]

Very cool...I very much enjoyed looking at the internals of the mysterious M96. Only problem is I don't know what I'm looking at half the time, as I've never taken one of these apart. As far as I know, there are no rebuilding books available like there are for air cooled? I know Charles and Jake Raby hope to develop a rebuilding guide as part of their flat6 program.

[Topless]

Very interesting write up. Thank you for sharing. So the freeze plug let go internally during an overheat condition?? I would not have expected that. Totally repairable. I have been getting a little intermittent grinding noise from the front of my motor lately (77k miles). Sounds like a water pump bearing. Time to take a closer look. :o

It looks like you have done this sort of work before. Did you use a service manual for the tear down or just take lots of pictures and wing it? I have been inside many Chevy/Toyota/Nissan motors but the M96 looks so...German. Any surprises along the way? What did you figure your costs would be for an electric motor conversion?

Edited January 5, 2009 by Topless

[txhokie4life]

Very interesting write up. Thank you for sharing. So the freeze plug let go internally during an overheat condition?? I would not have expected that. Totally repairable. I have been getting a little intermittent grinding noise from the front of my motor lately (77k miles). Sounds like a water pump bearing. Time to take a closer look. :o

It looks like you have done this sort of work before. Did you use a service manual for the tear down or just take lots of pictures and wing it? I have been inside many Chevy/Toyota/Nissan motors but the M96 looks so...German. Any surprises along the way? What did you figure your costs would be for an electric motor conversion?

My first time tearing anything down -- I'm the lackey is this duo -- Danny (in green) had rebuilt six 911 air cooled engines -- this is his first M96.

He took a lot of pictures, I bought a CD of the shop manuals from a guy on this board. Watched all the www.986fix.com videos.

Bought some of the special tools, Danny made the others.

I engineered what we would do when we found what -- found/ordered all the parts. Now I mostly clean any parts we are redoing and torque a few bolts :-)

But my eyes and ears are wide open! Picking anything up I can incase I decide to do this again some time.

Mike