Aasco flywheel is here. - Page 6 - 986 Forum - The Community for Porsche Boxster & Cayman Owners

insite · 07-07-2011, 10:11 AM

pressure plate:

insite · 07-07-2011, 10:15 AM

and a comparison of new vs. old friction surfaces. note the deformation present in the old friction surface near the fasteners. this tells me that either:

1. the factory didn't properly clean the flywheel & friction disk during assembly
2. one or the other wasn't machined flat (unlikely)
3. they over-torqued the fasteners (most likely)

BTW, the old friction surface only has about 12k miles on it. the new one w/ new fasteners, a new pilot bearing & a new torque plate costs just under $200 from aasco.

insite · 07-07-2011, 10:17 AM

result? pretty noticable. the vibration is gone & the engine is buttery smooth. i used to cringe when i revved it high. now, i beat the **************** out of it & feel great.

Jake Raby · 07-07-2011, 07:02 PM

What is illustrated here is a lot of imbalance, but it is what we see on a daily basis. For some reason no one wants to listen to our experiences, including the manufacturers of the imbalances components.

What is clear in the experience of insure is the fact that these assemblies require balancing before installation. This something we have known for a decade, but something that no one seems to concur with.

I gave up trying to share, we just apply our experiences to those who seek out our specialized services. Glad to see the engine is smooth now, at least we were effective.

Iflylow · 07-08-2011, 03:56 AM

Sounds like this one has been goin' for a while, and it's all over but the cryin'.

In aviation, we take harmonics very seriously, and I am constantly amazed at the fatigue which is caused by seemingly unrelated components. As a very graphic demonstration on harmonic resonance, go to youtube and search "helicopter resonance CH-47" (I'm trying to avoid any copyright problems by not posting a link)

If you aren't already convinced of the dangeers, you will be after watching this. If I remember correctly, This was caused by one blade which was out of balance with the rest.

Iflylow · 07-08-2011, 04:06 AM

BTW, Jake,
You get a lot of flame whenever you post ANYTHING! I appreciate anyone who takes the time to share information. I was new to Boxer engines, and spent hours reading your old posts. Last weekend, I changed clutch, flywheel, RMS, IMS bearing, water pump and thermostat myself. all the information I found on this site gave me the confidence.

Thanks from all the other lurkers who don't feel the need to shoot you down.

Jake Raby · 07-08-2011, 05:39 AM

Being a former CH 46E Crewchief I know all about harmonics and IPS.

As far as catching heat:
Anytime that anyone is in a position of authority within a group there are those who feel inlined to go out of their way to pick the person apart. Thats just life and in my world it doesn't matter. I learned years ago that at least 10% of the population can't be pleased and the majority of that percentage is the most vocal online. The tables turn when we are eyeball to eyeball and they are given the opportunity to take a stab.

I expect this to only get worse after my book is published as it includes a ton of info that defies conventional wisdom, because it is written directly from experience. The peoplewho appreciate what we create and share make it worth all the BS that the sharing creates.

The moral of this story is to never assume that the components that are removed from a box are balanced to a tight enough tolerance for direct install onto an engine.. Then never assume that these components will match well enough with associated components to allow for direct installation. Insite's flywheel was out of balance and so was his pressure plate, coupled together they created severe imbalance, even after being mated with 5 different position indexes before being corrected. Thanks to insite for being kind enough to post his experience, which helped me illustrate my thoughts on this topic once and for all.

I stay away from these flywheels and haven't installed one in over 2 years. It's clear that the only way for me to be pleased with a LWFW option for us us to make it in house, but I have more more important fish to fry with the time we have.. Dual mass works fine for us, we make big enough power increases with every engine not to need a LWFW to impress the driver.