Making a better air oil separator
 

Considering the AOS is an item sure to fail at some point with little notice, and the high potential for damage to the engine, it sure would be great if there was a version other than the Porsche design that would be easier to maintain and offer more reliable operation.

There are some smart talented people on this forum - is there anyone out there willing to come up with an improved design? I would think there is a decent market for an improved AOS. I have seen some great threads where guys have designed and installed a homemade AOS that seemed to work well. It would be awesome to never need worry about a smoke bomb attack!

Think I saw an aftermarket one in the $800 range IIRC!

There IS one in the DIY section.

Stelan made his own, and although he did not create a full DIY with pictures, he did describe it in enough detail with a schematic that a DIY'er could recreate what he made and has been successful with.

Here is the link to the thread: http://986forum.com/forums/performance-technical-chat/61861-more-stupid-aos-talk.html

With Stelan's design: http://986forum.com/forums/498956-post19.html

Looks like it has been working perfectly but we need a track tester and some more field reports as time goes on to see if it lasts.

Top it off, you'll be hard pressed to spend $75 to build it yourself.

Well, they may be failure prone but on the other hand they're all 10-15 years old.

A pretty good design to have lasted that long.

Wouldn't waste in effort thinking of alternatives ... unless you're an experienced automotive design engineer.

i think one of the things to note is that porsche has improved the design over the years - there are a number of iterations of the AOS. make sure you have the latest version and the likelyhood of failure is much less than the first version (which, if still on your car, is over 15 years old at this point).

+1. I would also not that we see many more aftermarket AOS units fail prematurely than factory units.

My version of an aftermarket AOS is about to be ready for sale, I wanted to have at least 5k miles of use in all driving conditions and it is reaching that point, it includes a long trip deep into central america from Texas and back. in the interim tooling was developed for fabrication. hopefully soon as I have been in Europe for a while due to work.

Stelan, you should make a thread about it and post some pictures! I want to see that ;)

Sure will, thank you

I cant wait to see it!!

Stelan is the only guy to actually Post a viable alternative system here. A few of us(me too) mumbled about Catch Cans but we never achieved anything.
It took a bit of prodding and encouragement from Forum members but Stelan was busy and the latest diagrams and improvements were well worth the wait.
What Stelan did not emphasize in his brief post above is that his system is a major simplification of the AOS system.
http://986forum.com/forums/498956-post19.html
It is worth reading the entire threads just to see how the concept developed.
http://986forum.com/forums/performance-technical-chat/61861-more-stupid-aos-talk.html
The simplification is important because it reduces the number of potential failure points.
The use of generic parts minimizes the cost & makes repairs/replacement easier- no special orders.
The generic parts can be upgraded from plastic to brass if desired.
The hoses can be upgraded to ones that do not split or crack. (Vacuum-specific Silicone)
The Stelan "AOS" is buried and would not be noticed as 'illegal' during the Visual part of Smog Check.
It is reversible, inexpensive,easily sourced and upgradable.
The Stock aftermarket AOS units are reported to be failing prematurely.Fitting a free replacement does not guarantee a good unit. Some are duds out of the box ! R&R of an AOS is a miserable job.Stelan's is much easier.
Rather like Ben006's ball-bearing Shifter and his Intake, Stelan's "AOS" may benefit from a little refinement during the concept stage but it is great home-brew answer to a chronic problem.
Thanks for helping us Stelan.

Stelan Aftermarket AOS