House started the swap this morning at 9am. The old engine was out after lunch.

The pro's make it look easy (as compared to my hack DIY skills!).

http://986forum.com/forums/uploads02...1524688909.jpg

So a 3.8L is going in Tom, I am sending the scrutineers

3.8's are soooo 2016. I assure you it'll be a 4.0 liter.

Tom... is it just the picture being somewhat distorted, or is that UDP all bent to hell?

I didn't take the photo so I don't know for sure but I'm going to guess that its a distorted photo. I plan to drop by the shop today and I'll confirm.

Everything has been swapped over and the replacement engine has been installed in the car! They should have it running by the end of the day. :D

They'll drive it on Monday to make sure that everything is ok and it should be ready for pickup on Tuesday.

The small pile of parts to the right of the top is the tip wiring harness, a/c compressor and lines, exhaust manifolds, and alternator (the bearing sounded rough so they swapped in the old one). The idler and tensioner pulley's were also replaced with new components since they were rough sounding.

http://986forum.com/forums/uploads02...1524849412.jpg

Photo distortion. The UDP is fine. :)

Ok, check this out....

Here is the oil filter from the failed engine just as it came out of the engine. It looks like the oil pump was sucking so hard that it collapsed the filter. Is that possible? Weird. :confused:

There wasn't any metal in the oil or the oil filter but the shop said that they found coolant in the oil when they drained it. There is also a ton of oil in the intake runners. I plan to get the engine back to my workshop and will disassemble it to try to determine the exact failure.

And at the bottom is a pic of the failed engine looking pretty sad after being raided for parts to swap onto the replacement engine. :(

http://986forum.com/forums/uploads02...1524850335.jpg http://986forum.com/forums/uploads02...1524850355.jpg


http://986forum.com/forums/uploads02...1524850381.jpg

blown AOS resulting in a broken ring?

I'm thinking that's the case -- was there any smoke out the back?

Mike

Let's try this one. Cracked cylinder/head #4/5 ? resulting in coolant in the oil. Oil filter is downstream of the oil pump so sees pressure not vacuum. Coolant saturated the paper filter media which swelled closed causing high DP across the media resulting in element collapse. Excessive vapor from coolant in the crankcase overwhelmed the AOS resulting in failure.

No smoke at all.

Replacement engine installed! Used engine runs great. I'll put some miles on it today and maybe run it on the dyno tomorrow...

http://986forum.com/forums/uploads02...1525193617.jpg

Failure mode #???

Yeah was going to say filter is post pump. I can’t think of another way that the oil filter collapsed other than it absorbed coolant/water. These are not designed for separating water. Maybe a synthetic media filter would have done better? I.E. spin on.

The other question is: did the coolant in oil make the AOS fail? Funny that there was no smoke but there was a ton of oil in the intake...

I’m thinking more and more that the AOS didn’t fail, that is was just oil starvation caused by the crushed filter, destroyed / spun bearing somewhere?

I'm guessing failure of the engine oil cooler or an internal freeze plug causing intermix> collapsed filter> blown AOS> Oil in the intake. The motor is full of goo but if no metal debris it may be salvageable.

I'm having the old engine moved to my house and will do a tear down. Stay tuned...

I drove the car about 60 miles around LA's freeway's today (mid-day to avoid traffic!). Had the opportunity to do a few 0-80mph runs while shifting at redline on the 110 Frwy north of downtown LA where the freeway on-ramps are about one car length. Engine seemed to have good (normal) power and ran perfect.

The only thing that I noticed was that the water temp was a little higher than it used to be - and then I remembered that I forgot to have the shop swap over the low temp thermostat from the old engine to the replacement. Guess what I'm doing this weekend? (might even replace the water pump while I'm in there).

Off to the dyno tomorrow...

The dyno wasn't available last week so I decided to just go to Willow Springs on Friday to test. I did 4 x 30 mins sessions and the engine ran perfect. It was easy to do 1:35 lap times on a fairly warm day. I'll try to get onto the dyno this week just so I know where this engine stands in terms of power.

The most interesting thing about an open test day is some of the other cars that show up...

Like this LeMon's Flying Pig car...

http://986forum.com/forums/uploads02...1525622600.jpg

http://986forum.com/forums/uploads02...1525622624.jpg


Or this BMW spewing fuel from the right rear corner on every left hand turn...

http://986forum.com/forums/uploads02...1525622660.jpg

Wow...:eek:

Some news what caused the engine failure? Oil filter looks pretty trashed. What brand was it?

Mahle filter.

I've been busy getting the car ready to race this weekend so while I've started the tear down, nothing of interest yet...

Someone took a video of my car this morning on the way to practice at Willow Springs and posted it on Insta. Practice went well and the car is running great. New tires this afternoon and then racing Sat and Sunday.

Video here: https://www.instagram.com/p/Bi7LB6egQLe/

http://986forum.com/forums/uploads02...1526678746.jpg

Another friend's post from Insta...

http://986forum.com/forums/uploads02...1526688627.jpg

#thstone_army

Well, my goals for this weekend were simple: don't crash and avoid major mechanical failure: Mission Accomplished!

With more than 20 Boxster's in the field, it was mighty competitive. In both races, I qualified mid-pack and finished around 14th. Not my best showing by any regard but it was good to simply get through a weekend of racing without any major problems.

Here is a short video of us coming down the Omega. I was chasing the #319 of Erin Vogel who passed me earlier in the race. Despite my best attempts, I was never able to get the position back, but it was really fun!

<iframe width="560" height="315" src="https://www.youtube.com/embed/7xmHzk_X0DQ" frameborder="0" allow="autoplay; encrypted-media" allowfullscreen></iframe>

Here is the video from the start of Race #1 on Saturday at Willow Springs.

One of the interesting aspects of this race is that the Green is thrown super early - I am just coming out of Turn 9 (and can't see the start tower) when we go Green and some of the cars behind me are still in the turn!

I make a nice pass to move up one position on the entry to Turn 2 and then defend into Turn 3.

Turn up the sound to hear the glorious symphony of 24 flat-six engines at full throttle and be sure to watch in full screen HD!

<iframe width="560" height="315" src="https://www.youtube.com/embed/4oT3mxRq3Wc" frameborder="0" allow="autoplay; encrypted-media" allowfullscreen></iframe>

good sh$@#t.. stuff Tom!

i gotta say that quiet before the storm and the start is still my favorite part! that sound is so glorious, who cares who wins! when you live that you are ALIVE! that's all that matters.

keep the videos coming and keep enjoin! LIVING THE DREAM!

Thanks and yes, its definitely living a lifelong dream for me. :cheers:

Here are a few pic's from last weekend...


With 24 cars, it was a huge field coming down the front straight at the start...
http://986forum.com/forums/uploads02...1527460103.jpg

On grid doing some visualization before the start of the race...
http://986forum.com/forums/uploads02...1527460138.jpg


Leading a couple of 944's into Turn 3...
http://986forum.com/forums/uploads02...1527460169.jpg\


A quartet of BSR's coming down the Omega through Turn 5...
http://986forum.com/forums/uploads02...1527460187.jpg


My friend Bart Hale telling me about driving his 996 GT-3 in the time trials...
http://986forum.com/forums/uploads02...1527460206.jpg

[QUOTE=thstone;571162]Here is the video from the start of Race #1 on Saturday at Willow Springs.

One of the interesting aspects of this race is that the Green is thrown super early - I am just coming out of Turn 9 (and can't see the start tower) when we go Green and some of the cars behind me are still in the turn!

Tom, if you look closely you'll see we didn't go green until 37 secs into your video when Anders and I were almost at start finish. It was a very LATE flag. We just decided to get going way before then LOL. You know what they say - go with the cars not with the flag :)

What really pissed me off was that the one time I was able to get the jump on Anders, Gene was still able to pass us both from the second row by turn 1. Sigh.

Whaaaat? I was so far back that by the time I got to the start/finish, you guys were already in Turn 6. :)

So yes, it appears to be a case of a super late green flag where the entire field jumped early. As you said, I heard everyone else going, so I went too.

Thanks for the clarification!

Why buy car parts when you can print them?

Recently got a Flashforge Creator Pro and it is amazing.

<iframe width="560" height="315" src="https://www.youtube.com/embed/j6VRsfErDx0" frameborder="0" allow="autoplay; encrypted-media" allowfullscreen></iframe>

Here are some pics of the prototype rally-style shifter that I printed.

This prototype was made from PLA so its fairly light but feels very strong/stiff. I would like a little more weight so I will print another prototype using thicker exterior walls along with a thicker interior honeycomb structure to see if that gives it a beefier feeling.

I will have to use ABS for the final part since PLA may start to deform at temps (~130F) that are likely to be experienced in a hot race car.

As you can see, it is quite a bit longer/taller than the carbon fiber shifter that I have been using. My initial impression is that I think that it needs to mount deeper on the shift lever like the carbon fiber shifter does.

I am going to drive it a bit like this and see what I think. Then I’ll drill the mounting hole 1” deeper and drive it again. And then drill it so it fits flush at the bottom and drive it again.

The final version can be printed in any of 40 different ABS-available colors. The cost is about $1.65 in material. It takes about 4 hrs to print but its completely automated so I start it and just come back when its done.

Note: My car has the 997 shifter which has a shorter throw than the stock 986/996 shifter, but not as short as an aftermarket short shifter.

And no, you weren't the first to think that it looks like a big blue dild... :D :eek: :cool:

Existing carbon fiber shifter...
http://986forum.com/forums/uploads02...1530557866.jpg

Prototype shifter...
http://986forum.com/forums/uploads02...1530557907.jpg

To give you an idea of the size/dimensions...
http://986forum.com/forums/uploads02...1530558012.jpg

Side by side comparison...
http://986forum.com/forums/uploads02...1530558043.jpg

Been interested in 3D printing, which printer are you using? I was check8ng out some software that you can use your camera to make several photos and convert into a 3D model for printing.

Very cool!

I talked to a racer who mentioned that if you want to prevent a money shift
force your shifting pattern to not be Thumb on top, but on the side.

might consider building a shifter that promotes that grip as opposed to the thumbs up.

It has to do with the elbow bending direction, thumbs up it is easy to pull towards you, sideways thumb will make that movement more difficult -- and therefore less likely to be done unintentionally.

I also had issues with a non-rounded top as it dug into my palm.

M

I'm using a Flashforge Creator Pro: Creator Pro 3D Printer – FlashForge 3D Printers

I am still a novice but its pretty easy to set up/use and thus far has been super reliable. There is a lot of help online in forums but I mostly use the default settings and have had good results.

I'll have to think about the hand positioning - avoiding the money shift is always a good thing!

And yes, I might have to play around with the top edge to find a shape that is comfortable in my palm.

Nice! Just name the shifter Steely Dan!

I was looking at the software just the other day, trying to see how we could apply its use inside our company. I am the IT Manager for this site, we have a engineering design section that might could use this technology. But other than wanting to just print car parts in my office I can not come up with a valid reason for the company to spend the money so I can learn how to use one!:D

Been busy with work but finally got back to the shifter. The throw length is about right with the knob mounted fully onto the shifter as shown below. I also filed the top edge to give it a more natural feel in my hand.

Planned design changes: deepen the mounting hole, add more chamfer to the top edge, thicken the walls and internal honeycomb for more strength, and add a reinforced boss for a flanged expansion insert/retaining screw. Then I'll print Version 2 in a more appropriate color (white or black) sometime this week.

http://986forum.com/forums/uploads02...1532213535.jpg