Blue boxster resurrection project

[Homeoboxter]

Originally Posted by alynch

I love your write-ups. It makes me want to tackle those projects I’m always hesitant to start. Thanks for talking the time to document all your efforts. BTW, you must have some workshop and supply of tools!

I`m glad you enjoy reading this project, I hope it`ll help others as well to do a similar job with fewer mistakes than I make I just work in my garage, I accumulated a bunch of tools for other projects over time and just order new ones along the way.. That`s why it`s taking so long!

[Homeoboxter]

Hey Folks,

I haven`t posted for a while, the project has slowed down a bit. Spring is near though so I better speed up this restoration. At last I received the ring set for the engine. It`s not identical to the original but I think they should be fine.

Here they are:


The second is different from the original in design, different solution for the same function:



Top rings, old and new, side by side: no big difference in gap:



Same for the 2nd ring:



What was really worth the investment is the oil ring set: quite a bit of wear and deteroriation on the old ones. These rings were stuck in the piston groove in gunk.



After a slight hone on the bores they have to be ok.

I made some progress on pinning the IMS too. I realized that there is some chance for each of the three gears to spin on the shaft so I decided to pin all of them. Although I couldn`t see any sign of rotation of the gears with respect to the shaft, I made sure they are all aligned. The gear tooth on one side has to be in line with the gear trough on the other ( I looked at several IMS pics on the web to confirm this) :



Not only the shaft but also the gears are made of some surprisingly soft steel that`s quite easy to machine.



I tapped the holes with an M6 tap. I didn`t make the thread all the way through so the set screws will get stuck at the bottom.



Here`s how they look, the gear on the other end is pinned as well. They are not tightened down, hence they are sticking out. I`ll need some good permanent thread locker to finish it.

[Homeoboxter]

Hey,
Last weekend I gave a light honing for the cylinders to get them ready for the new rings. I used a deglazer that`s free to rent at Autozone. Here`s a few pics of the tools and the result.

[iscle]

I'm loving this rebuild!

Any news?

[Homeoboxter]

Originally Posted by iscle

I'm loving this rebuild!

Any news?

Hi, not much unfortunately, I`ve been working on my other car and didn`t get around to the Boxster. Except for the belt pulleys, they didn`t have a healthy sound so I rebuilt them fresh bearings instead of buying new ones.



A spark plug socket perfectly fits through the pulley and gets access to the bearing.





I used SKFs instead of the original FAG products.




After placing the bearings in the freezer and heating up the pulleys with a heatgun they slide right into their places after a few punches with a hammer. Make sure to use a socket that fits the external ring of the bearings.



These should be good for the next 100k miles.