Swapping engines - 986 Forum - The Community for Porsche Boxster & Cayman Owners

LoneWolfGal · 03-01-2025, 06:45 PM

The 3/8"-drive socket will now fit in the notch and on the nut, I'm happy to report. It took a while to grind it down enough, and it wasn't easy. As I said, the steel is tough. Tough enough that an old drill bit I had wasn't up to the task of drilling out the hole for the screwdriver to go through. I'm going to knock off for tonight and hit it with a new bit tomorrow. In the meantime, here's my grinder setup. Note the quarter-inch high pile of steel particles on the paper towel. Needless to say, I wore a mask, nitrile gloves, and eye protection. The bottom photo is a comparison with the 1/4"-drive socket.

NOTE TO SELF: Get a bench grinder, for God's sake. This would have been the perfect application for one.

piper6909 · 03-02-2025, 07:26 AM

Quote:

Originally Posted by LoneWolfGal

NOTE TO SELF: Get a bench grinder, for God's sake. This would have been the perfect application for one.
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There are so many ways that could be done without a bench grinder.

You could use one of these to attach the socket to a drill and run it at high RPM over a stationary sheet of sandpaper, or a metal file, or even a grinding stone running in the opposite direction.

LoneWolfGal · 03-02-2025, 11:15 AM

Quote:

Originally Posted by piper6909

There are so many ways that could be done without a bench grinder.

You could use one of these to attach the socket to a drill and run it at high RPM over a stationary sheet of sandpaper, or a metal file, or even a grinding stone running in the opposite direction.

Good idea, Al. And it probably would have been easier than my improvised grinder. However, I had a very good reason for not going that route: I didn't think of it.

piper6909 · 03-02-2025, 03:19 PM

Quote:

Originally Posted by LoneWolfGal

Good idea, Al. And it probably would have been easier than my improvised grinder. However, I had a very good reason for not going that route: I didn't think of it.

That's an excellent reason. Had I known what your approach would be I'd have suggested it sooner. Regardless, you got it done and that's all that matters.

LoneWolfGal · 03-02-2025, 08:14 PM

I swear, I've been plagued with obstacles during this entire project. The latest obstacle arose when drilling out the socket. I saved the drilling for last, thinking it would be a snap. It turned out to be an order of magnitude more difficult than shaving down the socket's diameter. I broke a new drill bit trying to get through the socket's two internal partitions. That was disheartening. I'm not equipped properly. Clearly, a drill press is needed, and I'd like to have one someday, but for now I think I'm going to take the socket to a local machine shop and have them do the honors. I know those guys. I'll take a short case of Coors with me.

piper6909 · 03-03-2025, 03:41 AM

Quote:

Originally Posted by LoneWolfGal

I swear, I've been plagued with obstacles during this entire project. The latest obstacle arose when drilling out the socket. I saved the drilling for last, thinking it would be a snap. It turned out to be an order of magnitude more difficult than shaving down the socket's diameter. I broke a new drill bit trying to get through the socket's two internal partitions. That was disheartening. I'm not equipped properly. Clearly, a drill press is needed, and I'd like to have one someday, but for now I think I'm going to take the socket to a local machine shop and have them do the honors. I know those guys. I'll take a short case of Coors with me.

They'll definitely make quick work of it. But if you want to give it another shot yourself, clamp the socket on a vise (I'm sure you have) and start with the smallest bit you have that's just bately too big for the existing hole. Drill through, then go with the next size bit and repeat until you've reached the desired diameter.

LoneWolfGal · 03-03-2025, 10:11 PM

Quote:

Originally Posted by piper6909

They'll definitely make quick work of it. But if you want to give it another shot yourself, clamp the socket on a vise (I'm sure you have) and start with the smallest bit you have that's just bately too big for the existing hole. Drill through, then go with the next size bit and repeat until you've reached the desired diameter.

Yes, I started with 17/64", which was one 1/64" larger than the 1/4" holes in the internal partitions, figuring to proceed to 9/32", 19/64", 5/16", etc. all the way up to 3/8", the objective. After laboriously drilling its way through the first partition, the 17/64" broke in two. Maybe it had a structural flaw. I'll try the 9/32" before I take it to the machine shop. However, I'm pretty busy with a house purchase, so I'm not sure when I'll get a chance to find out.

At least the Solution is installed, except for torquing the flange and stud. The rear main seal will take only a couple hours, but I expect the cam chain wear pads to be a multi-day project, since I haven't done it before and I tend to be ultra-cautious and mega-meticulous with new procedures. In any case, I plan to finish the swap here before I move all my tools to a new house in a different town.