Blue boxster resurrection project

[particlewave]

It’s always great to see people try new things. Can’t say I agree with using two different bearings (as an engineer, I see many issues with this...a larger roller bearing seems better to me as thrust forces in this application should be minimal), but I am interested to see how your oil gallery works out.

Of course, it will take at least a few years and tens of thousands of miles, plus pulling the bearings for inspection for a definitive answer, but I hope to be around for that.

Very innovative. I will be watching with interest.
I hope your theory pans out

[Homeoboxter]

Originally Posted by particlewave

It’s always great to see people try new things. Can’t say I agree with using two different bearings (as an engineer, I see many issues with this...a larger roller bearing seems better to me as thrust forces in this application should be minimal), but I am interested to see how your oil gallery works out.

Of course, it will take at least a few years and tens of thousands of miles, plus pulling the bearings for inspection for a definitive answer, but I hope to be around for that.

Very innovative. I will be watching with interest.
I hope your theory pans out

Thanks! I think I will have to replace the DMF in about 5-10k miles, so I`ll have a chance to inspect the bearings as well. Hopefully it won`t fall apart before that

[Homeoboxter]

Everlasting boxster project: I haven`t touched the thing for a while, and now instead of progressing forward, I took a step back and split the crankshaft bearing housing to take a peek into the main bearings. Luckily they all are in fantastic condition. Maybe I`ll check the clearances with plastigauge just in case, but there`s no apparent sign of wear.
Here are a some pictures:

[Hirsch990]

Glad to see an update. I was wondering what was going on.

[Homeoboxter]

Yeah, every project is getting delayed since the little one arrived. Hopefully the Boxster will run at least when he gets the license Thanks for keeping track of the progress!

Originally Posted by Hirsch990

Glad to see an update. I was wondering what was going on.

[Homeoboxter]

Update: I was a bit too optimistic last time when I said everything inside the crank bearing housing was in perfect condition. I lifted off the crankshaft and took a second look. I discovered a few things:

1) The most shocking is this by far:




I assume this piece was already missing in the factory, otherwise I can`t really see how it could have escaped from here without getting jammed in between the journal and the bearing. Must have been a late Friday session on the assembly line when this got through quality control. Actually, if it was just fine for 100k miles, I might as well put it back, right?

2) I still could find pieces from the plastic chain tensioner pad that fell apart. This little thingy is a real pain in the butt. Make sure you replace yours in time! Makes a lot more sense to replace these regularly than any IMS update.



3) One of the thrust washers seems a bit more worn than it should be. Looks like it got mixed with some plastic from somewhere, or just burnt, I don`t know.




The other one, that`s not pushed by the crank when the clutch is being operated, seems brand new.



4) When the casing was machined, these ugly burrs should`ve been removed I guess. They come off easily and can cause damage anywhere they get to. German precision, where did you go?




More to come once I received the parts.

[Qingdao]

Originally Posted by Homeoboxter

...4) When the casing was machined, these ugly burrs should`ve been removed I guess. They come off easily and can cause damage anywhere they get to. German precision, where did you go?
...

I interviewed for a position at Mercedes Benz Vans last year (its a local production facility). One of the interviewers said "Perfection is an unobtainable goal; we just do the best we can." LOL