I can answer the emissions part.

I dropped the entire catalytic system and installed headers with pipes. After a tune the car picked up about 30hp. I live in CA so I have to deal with emissions. I installed ARP header studs. This makes dropping the headers, and swapping the cats in for smog about a 1 hour job for me. (I installed all new O2 sensors when I put the headers on) As for the check engine light, I use FVD Brombacher O2 sensor extenders/mini cats. This tricks the secondary sensors into thinking there are cat converters.... No CELs :D

When installing the headers I wrapped the P/S line, and the coolant hose. The headers are really close to them.

Thanks Qckslvr; these thoughts will come in handy; 30hp gain! that is impressive...which tune? We only have 91 octane at Mile High (Denver) unless you purchase race gas 100 octane @ $9.40/gallon

wish I could tell you the tune, it was done by S-Car-Go in San Rafael, CA :(

Thanks. Car's 19th birthday this month. 46k on the clock. Seven year old BFGs removed with lots of tread left. Will probably buy a new set in 7 more years, if I live 7 more.

Getting ready for AX season:
Removed my rattling second-hand charlie chan exhaust.
Ordered a new muffler, TPs, header wrap, and a trailing arm.

Careful with header wrap on your headers. The M96 is somewhat prone to oil leaks via the spark plugs tubes, cam covers, and a variety of other spots and they can/would drip right onto the headers potentially. Another potential issue if you have the stock power steering system in the car, is the overflow dumps PS fluid right on top of the engine, which can also drip down and land right on your wrapped headers. I had a minor fire that fried an O2 sensor from the above. If you are trying to protect your PS lines from heat, you are better off wrapping your PS line and O2 sensors wires and leaving your headers alone. Not a chance would I risk wrapping my headers. YMMV

Thanks - I wasn’t aware of that.
The original intent was to wrap the TPs to keep heat off of the axle CV boots and other lines in the area, as the stock cats have heat shields.
I *think* these are clear of the leaky bits on the engine but will certainly check now.

Took off the front bumper to replace a grille with a broken slat, and found I bought the wrong grille. My car has the Aero Kit. While in there, I cleaned out the radiators.
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ceramic coating rocks the party. highly recommended.

It really is amazing how much stuff gets sucked in between the radiators and the condensers. Mine were dirty, yours have considerably more. It must run cooler now.

WOW:eek: that’s a lot of blockage there! Now I may have yet another “project” for this spring!

You definitely want to wrap your main PS line either way. That thing sits right next to the header and a PS leak onto a hot header is POOF for sure. PS fluid is VERY flammable.

I wrecked it :)
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I’m taking a 250 mile trip in my car today and returning tomorrow. This will complete 1,000 of the 1,500 break-in miles I need on my just rebuilt 3.2 converted to 3.6 with LN Nickies. In addition to having a new 987 motor mount installed, I also had the Function-First “Sport” motor mount insert and upgraded transmission mounts installed. I don’t find them to be harsh at all so far.

I'd like to know about those screened vents you've cut in the fender liner. Can you share, please?

Picked up car from maintenance and with new FVD Brombacher sound version muffler installed. Great sound more flat six, but not too much more.

Sure! It's just expanded metal mesh from Home Depot. I used aluminum, I think it's intended use is for gutters.

• I pulled the whole fender liner out
• Determined the shape I wanted based on the bracing behind the radiator.
• I cut the liner with a cutoff wheel. I wanted the corners rounder than they ended up. I used a 1/2" drill bit, it would have looked better with a full inch.
• I had to cut out some of the original radiator shroud so the air could pass straight through. I used a hacksaw blade. A dremel would probably be better.
• Cut my mesh to shape
• Drilled some holes, and riveted it in place.

Congratulations! My goal is to acquire an FVD Brombacher sound version.

Thanks! I have had mine for several months, so pretty excited. My tech was borderline on likening the sound I think he thought it should have been louder. Most of his clients want louder. For me tone is perfect, just a little louder than stock but deeper, opens up over 3k but cruisin at 3100 nice sound but not over powering.

My next upgrade is plenum throttle body. :D

I have the FVD Brombacher as well with headers, and test pipes. I was really expecting the car to be loud. But I am very happy with the FVD. Like mentioned above it has a great note, and no drone at cruising speed. But for me, when I get the car up around 5k it lets out a nice bark and really has that Porsche flat 6 growl.

say WHAT? :eek:
:ah:

I am liking the feedback; I don't want loud, droning, but nice deep tone

Cleaned and rebuilt the door latch that was giving me window problems, kinda a pain in the butt but all is good now.

I finished my 500 mile two day road trip, mostly highway with some traffic jams and city traffic. I averaged just under 23 mpg, using 4th, 5th and 6th gears on the highway to vary my engine speed during the break-in period. I've got about 500 miles to go until it is broken in and the oil is changed.

I will try and remember to get a db reading at idle and 3k. Iforgot to get a stock reading, but will give you an idea.

This muffler is one of my favorite modifications. I have had it for maybe 6 years and I added test pipes a few years ago. Zero drone and barely louder than OEM when cruising, but awesome flat 6 sound upon any acceleration, especially full throttle and high RPM. Highly recommended!

99 986 engine mount removed
 

Removed my engine mount and wow the bushing just slid out pushing with one finger.

https://youtu.be/aFAvyMW2AhA

https://youtu.be/i_A6maJQKJ8

Did some maintenance, new plugs (decided to try some NGK 94279 FR6AHX-S Ruthenium HX Plugs), oil, air and oil filters, plus some injector cleaner in the gas tank.

Then took her out for a nice drive. Ran across some Black Mercedes AMG, not sure what model, but he wanted to play. So we did and I made him look bad. The best part was when he finally gave up. We hit a straightaway at around 50 MPH after coming out of some roundabouts. I was about 6 car lengths in front of him and he started coming at me again and I nailed it and was pulling away the whole time. Saw him give up, I looked at my speedo and was at 110 MPH. The dude didn't even try to pull up and give me a thumbs up lol.

I see you have 996 TB, and exhaust upgrades; do you think those upgrades were the result of your sprint race with the AMG?

Oh yes they help, but the most seat of the pants power gain I felt was when I did the 987 Air Box, K&N Air Filter, 76mm Intake Pipe, 996 76mm TB and 997 Distribution T install all at once. Man it really helps this engine breath and made a very nice roar in the intake. I felt a power gain with the headers, secondary cat delete and Borla muffler, but the exhaust sound was more surprising. Nice deep sound that lets people know she isn't stock.

She roars on the intake and exhaust now. Had my nephew drive on the highway in his car as I came up from behind him full throttle. He said he could hear me coming and shocked him when I went by from the sound. He said it sounded like a proper sports car. Should have had him pull out his iPhone and film it, but wasn't thinking about it at the time.

About a month ago I ran into another 986 and the guy was all over me to play. It was only a straightaway, no turns and I just walked away from him like he was driving Ford Pinto. It was boring for me, but he must have sure loved it as he kept pulling back up to run again and again lol.

Yep... pretty typical. Mine did the same.

Replaced Rear Track Arms. Actually bought a 21mm combi wrench, unlike a couple guys on YT who used channel locks to hold the nut.
Thanks CJ_Boxster for the tutorial.

First day out with the top down. Its like getting a new car every spring. I am always impressed with this car. An acquaintance realized that he will never finish his air cooled Porsche project and offered to trade me so I have my fingers crossed. I can always find another good Boxster (I hope)

I tried to change the AOS. The mounting bolts must be original, because they are far tighter than a 6mm should be. I got the lower loose, but the top one is shrouded such that, one-handed, I can't keep good pressure on it with a ratchet and it slips off. I even tried applying pressure with a long screwdriver through the wheel well with no luck.

Yesterday I went to clean the Mass Air Flow Meter on my car. When I was trying to get it out, it was not coming out by hand. So I grabbed a pair of pliers and pinched onto one edge of the MAF connection flange, to make sure I didn't break it. I finally got it out and I saw something fall as I was pulling it out. On the side of the MAF there is a little panel that is held in by some type of adhesive. See picture marked with red for this little panel area.

https://i.postimg.cc/KYPPPrZm/mas.jpg

I'm lucky that somehow this panel got stuck at the MAF area or it could have easily went into my intake system. I didn't take any pictures at the time as I was too busy cleaning out the old adhesive that was more like sticky mushy gunk then anything at this point. I finally got it all cleaned out, being careful not to damage the wire and resistor on the other side. Used some Permatex Black Silicone Adhesive Sealant to attach the panel back to the MAF. The Permatex directions says it takes 24 hours to fully cure. So I have been waiting patiently for the adhesive to fully cure. Got the MAF back in the car and took her for a nice easy drive. It works perfect, so no damage had been done. I wasn't getting any weird readings on my Durametric and no CEL. Glad I decided to clean the MAF and found this before it became a major issue for me.

I didn't feel like getting back into the engine bay after the drive to check the MAF and make sure that panel is still fine, but tomorrow I am going back in there to make sure.

Wonder what made the adhesive give out like that? You would think Bosch would use something that didn't turn into sticky mushy gunk and let that panel come off. Or maybe the CRC MAF cleaner isn't very friendly to that adhesive over time? I have cleaned the MAF on a yearly bases with this stuff.

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Went for a ride after finishing the new look. Stickers add at least 5hp!

More pics in the Show & tell forum.

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Mine were like that, star drive, even. I got the bottom one out, but couldn't get the top one. Finally ended up putting the handle for my cycle lift inboard of the AOS and against the transmission and just pried it. It's only plastic, you're gonna replace it anyhow, so break it. I didn't bother with messing with the bellows clamp, either. Just yank it out. They sell a replacement bellows clamp with a blue thing that holds the clamp open--this little handle is worth the price of the clamp (it's reuseable.) I don't worry about next time, I'll repeat the breaking and yanking. Makes it easy. btw, I used a slight grease film on the inside of the bellows, it slipped right on the crankcase port, easy peasy.

Gave the 2000S it's first washing of 2019 on a sunny spring afternoon, vacuumed the interior well, cleaned the glass, and applied Rejex to the wheels then an application of Griot's speed shine. The car looks so good part of me wanted to keep it in the garage to admire... but it's not a garage queen, it's a car so I took it for a nice, top-down drive. When I parked it back in the garage, I admired it again.

While I miss all this while it's in storage Nov - April, when I take it out, it's much like the renewal of the earth in Spring.

Larry (the Bald Eagle)

Well... not today...
 

Saturday the 85 degrees called for a drive into 92262.

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Major service
 

Took it to a local indy and had it steam cleaned top and bottom.
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Changed Oil, Filter, Trans Oil, Fuel Filter, Intake and Cabin Filters; Flushed PS Fluid.
I used my combo shallow oil drain/holder. I didn't realize that emptying the oil from the Boxster was like a cow pi**ing on a flat rock. Made a mess!