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Extra fittings when changing exhaust boxes

heed

Well-known member
Joined
24 Jan 2019
Messages
98
I'm going to be getting the switchable cat-back exhaust from TopGear soon. My plan is to have it fitted at local Indy or by a mobile mechanic.

As well as the exhaust, what other fittings would it be prudent to replace or that I might need ahead of time?

I'm thinking things along the lines of clamps/sleeves or new stainless steel bolts for example. I figure I might as well get any cheap things replaced that end up being loosened or removed to change out the exhaust.

Link to exhaust kit is here: https://www.topgear.co.uk/porsche-911-996-carrera-valved-cat-back

Currently I have the original boxes and cats on. Keeping the cats for now. I get a drip on the joint between cat and boxes, so wondered if I should buy new sleeves/joints?
 
The back box brackets will likely be rusty. As they are insanely expensive I had them rubbe down and painted. You can also buy a fixing kit for other bits and pieces from design 911.
 
2 x Beer cans
Silicone seal
 
Alex said:
2 x Beer cans
Silicone seal

:floor: I did see your earlier thread, yes.
 
The manifold bolts can be problematic - in a recent thread 8 of 12 snapped off in the heads. If you're fitting new manifolds, I'd be inclined to take it to a Porsche indy as drilling and tapping is best done on a ramp and they will have encountered this before.


Some replace with titanium others stainless. I'm erring towards stainless studs and nuts rather than bolts.
 
He's not going anywhere near his manifolds, just changing his back boxes. Best not to make a headache out of it.
 
INWB said:
The back box brackets will likely be rusty. As they are insanely expensive I had them rubbe down and painted. You can also buy a fixing kit for other bits and pieces from design 911.

Do you have a link to the exact kit I should buy? As I've not done this before I don't know what comes with the exhaust kit versus what you're expected to re-use from the existing stuff on the car.

Many thanks!
 
I've just ordered a dansk fitting kit from car parts for less <£30 delivered
 
I used the Dansk kit from Design911 as well. It comes with everything except the spacers and metal meshy dampeners that attach the silencers to the brackets. The exhaust tip clamps alone cost more than the whole kit!

https://www.design911.co.uk/fu/prod13006/Mounting-Kit-for-Rear-Exhaust-Porsche-996-Carrera---GT3/

My suggestion is to not even attempt replacing the silencer without the kit. At least the long bolts holding them to the bracket will definitely need replacing, but likely the clamps as well.
 
My long bolts that go bolt the silencer to the brackets were very badly rusted to the tubes that they run through. I used new stainless bolts from ebay and made new ali tubes from the raw metal stock available in B&Q's Porsche parts department. They will never rust or seize again. Also the solution was a fraction of the cost of buying the same bolts/tubes from D911 or an OPC.
 
Martin996RSR said:
My long bolts that go bolt the silencer to the brackets were very badly rusted to the tubes that they run through. I used new stainless bolts from ebay and made new ali tubes from the raw metal stock available in B&Q's Porsche parts department. They will never rust or seize again. Also the solution was a fraction of the cost of buying the same bolts/tubes from D911 or an OPC.

I did exactly the same - replaced the bolts (long and short) with stainless ones off ebay: https://www.ebay.co.uk/itm/201002656150
I also replaced the tubes, as they had fallen to pieces.
 
P0tential said:
I used the Dansk kit from Design911 as well. It comes with everything except the spacers and metal meshy dampeners that attach the silencers to the brackets. The exhaust tip clamps alone cost more than the whole kit!

https://www.design911.co.uk/fu/prod13006/Mounting-Kit-for-Rear-Exhaust-Porsche-996-Carrera---GT3/

My suggestion is to not even attempt replacing the silencer without the kit. At least the long bolts holding them to the bracket will definitely need replacing, but likely the clamps as well.

I have the Dansk kit coming today. Could you re-use the spacers and meshy dampeners or did you have to source those as well?
 
Kingb4 said:
Martin996RSR said:
My long bolts that go bolt the silencer to the brackets were very badly rusted to the tubes that they run through. I used new stainless bolts from ebay and made new ali tubes from the raw metal stock available in B&Q's Porsche parts department. They will never rust or seize again. Also the solution was a fraction of the cost of buying the same bolts/tubes from D911 or an OPC.

I did exactly the same - replaced the bolts (long and short) with stainless ones off ebay: https://www.ebay.co.uk/itm/201002656150
I also replaced the tubes, as they had fallen to pieces.

Are the tubes shown on this diagram?

https://www.dropbox.com/s/z9f6pvbuignf2aa/Screenshot 2019-06-10 10.18.01.png?raw=1

I'm just trying to get a part so I can either get them ahead of time or get dimensions to make some new ones. Thanks!
 
heed said:
Are the tubes shown on this diagram?

https://www.dropbox.com/s/z9f6pvbuignf2aa/Screenshot 2019-06-10 10.18.01.png?raw=1

I'm just trying to get a part so I can either get them ahead of time or get dimensions to make some new ones. Thanks!

Looks to be part 35 on the diagram. I made mine from aluminium tube with an inside diameter of approx 8mm, the wall thickness was approx 1mm. Just a case of cutting it to length and pushing it through the steel-wool damping washers (at the top and bottom). I happened to have some already in the garage, but am sure B&Q or homebase will have something suitable. Saves paying the porsche tax......
 
Kingb4 said:
heed said:
Are the tubes shown on this diagram?

https://www.dropbox.com/s/z9f6pvbuignf2aa/Screenshot 2019-06-10 10.18.01.png?raw=1

I'm just trying to get a part so I can either get them ahead of time or get dimensions to make some new ones. Thanks!

Looks to be part 35 on the diagram. I made mine from aluminium tube with an inside diameter of approx 8mm, the wall thickness was approx 1mm. Just a case of cutting it to length and pushing it through the steel-wool damping washers (at the top and bottom). I happened to have some already in the garage, but am sure B&Q or homebase will have something suitable. Saves paying the porsche tax......

Thanks. That makes sense. Weirdly number 35 doesn't have an associated part number. That's the first time I've found a part diagram that doesn't have an associated part number in the 996 parts PDF :dont know:
 

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