That engine sounds like it will be awesome. Unbelievable combination. If I understand right - this will be an engine that revs quickly and puts horsepower/torque down with a result of not having the highest top speed for the bore? Perfect for the US with speed limits - not the top end of an autobahn car with unlimited speeds.

Another piece of the puzzle purchased today a Fidanza lightweight flywheel. Got lucky and found one on fleabay at a reduced cost. Jake it's coming your way !

I thought that the lightened flywheel was a no go, due to balance issues.

Not an issue when you are building the engine up from scratch and balancing everything.

I'd never use the lightweight flywheel unless we were using this crankshaft... I also make a lot of changes to things, including the knock sensors, and their sensitivity. It's very risky business, but I live to take risks and learn from them.

No risks on this one, I took the risks to support these initiatives with test engines years ago.

Yes, I dynamically balance everything in house, and I'll do this one personally. Here the person building the engine will do 100% of the tasks associated with that engine.

We don't look to outside manufacturers, or farm work out. We don't have to.

Ok, it makes sense when you balance all the parts together.

But, when the time comes to replace your light weight flywheel with a new one, how do you balance the new replacement…?

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I'm no expert on flywheels so hopefully Jake will chime in. But I'll take an educated guess. The flywheel I purchased has a replaceable surface. So if/when the surface wears down you don't replace the entire flywheel you just replace the wear surface. The bulk of the weight has to be the mass of the flywheel so I don't think balance will be off by just replacing the flywheel surface.

Even if you just replace the surface, its still a moving part. Seems like a lot of extra work and extra variables. I thought the point was to reduce both.

I spoke with jake about this and it's a non-issue. Jake has all the info stored in a computer. If/when in the future the flywheel wear surface has to be replaced he can pull up the data and replicate the balance. It's VERY NICE dealing with someone that is a true expert in his field ! :cheers:

Much easier than it would be with a oem dual-mass flywheel.

A couple of months ago someone who bought an engine from me in 2007 grenade the pressure plate that I had fitted and balanced when I built the engine. I pulled up his file from the balancer and matches the balance in less than an hour.

These are the reasons why we do all work in house, and depend on no outside resources.

WOOHOO the lightweight flywheel arrived at Jakes facility today ! He will start balancing tonight we are getting closer ! I'm thinking by this time next month you will hear a rumbling off to the east........that will be my engine roaring to life ! :D

I am following this thread with great interest. If going from a 3.2 to a 3.6 were to pick up substantial horsepower and torque, It'd change the personality of the car tremendously, keep up the good work guys!!

Slight setback :mad: The Fidanza flywheel I ordered which was supposed to fit my application did not. Turns out after sending pics to Fidanza they admitted they had a run of flywheels that they mis-labeled and therefore won't fit. The vendor I purchased from has been very diligent in getting Fidanza to issue a RMA and call tag. Jake ordered an Aasco and had it overnighted so we are back on plan. He sent a few teaser pics last night she is coming along nicely :D. I've got the S up on my lift today I'm going to install the GHL muffler that we are going to use for the 3.6 . I also have a Porsche Motorsport front spoiler lip to add to the 996 GT3 front bumper. Hey she's got to look good right ?

Like normal, the Aasco was 8= grams out of balance. I documented all of this for Aasco, for a complaint.

I'm assembling it now.. There's no other way to achieve 3.6 like this in the world.

Its far from a conventional combination. Thats what happens through 10 generations of development. Its why all the others try to copy us..

Good luck with that this time, copycats!

I installed the GHL muffler today wow does that sound great ! Sounds like a 917 flying down the Mulsanne straight :D . Unfortunately I had it too close to my new diffuser and it rotated up during a spirited drive and burnt the paint :mad:. But it can't be seen but still make me mad. The motorsport splitter went on with few issues and looks good. I'll only post pics whe the car is complete with the new engine. :cheers:

Late yesterday I got the call from Jake that I have been waiting for.........the short block is done and he is now ready for my car !!! Still working out the drop off details on when but sometime next week I'll be dropping off the S . There are some items on my current engine like exhaust, intake manifold, wiring harness etc. that will be transferred over to the new engine. Getting closer :D

Really looking forward to hearing more about the specs of the engine and how it compares to your stock 3.2. I have ridden in a Renegade V8 boxster, and it was truly one of the most amazing experiences I've ever had - completely transformed the car. That power lets you do things very differently. I'm hoping you get a taste of that with this build!

Jake and ffuerst911sc.

Good evening to you both. This sounds truly amazing. Respects must also go to the loveablity of the gorgeous machine called a boxster in being such an object of beauty that is brings both artist and patron together with a take-it-to-a-new-level project like this.

It is more than a car, being typically Porsche, it is a love affair that never ends. A bond measured not in horse power, but in friendships.

Looking forward to the thrill of seeing new posts on this.

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I have said in previous posts if you're a number cruncher and every penny you spend has to make money then this isn't for you. On a balance sheet what I'm doing makes no sense. But being an enthusiest it makes perfect sense. I have been fortunate enough to own five Porsche's in my lifetime. Each one was enjoyed and modified for my pleasure. I made money on some and lost money on others but I enjoyed each one of them to the fullest. I am getting closer to retirement and made the decision that this will probably be my last one so I want it to be exactly as I want it. And I believe in just two to three more weeks it will be :D To me she will be a sleeper that will surprise a few folks. I'll drive it to work when sunny, autocross her as much as I can and squeeze in a few DE's. She will be driven no garage queen.
But who know's maybe in 5 years Jake calls me to let me know he's building 5 litre flat sixes and am I interested ? Stay tuned :D