Project WP0ZZZ99Z2S603158

samba-lee · 6 Oct 2013

Hi all,

I've just bought myself a C4 Tip S and plan on going through the various issues over the coming months and documenting them here.

Formally a 993 owner (you may remember me), I'm so keen that my first photos here are detailing ones

whoareya · 6 Oct 2013

Never mind detailing the car - winter is coming, so get that fence re-treated.

samba-lee · 6 Oct 2013

whoareya said:
Never mind detailing the car - winter is coming, so get that fence re-treated.

Who cares about a fence

T8 · 6 Oct 2013

samba-lee said:
Who cares about a fence

I would ..... if it clashed with my seats. :grin:

Best wheels for a NB 996 btw. :thumb:

samba-lee · 6 Oct 2013

T8 said:
samba-lee said:

Who cares about a fence

Click to expand...

I would ..... if it clashed with my seats. :grin:

Best wheels for a 996 btw. :thumb:

ha ha ha,

to be honest I'd prefer 17's for the ride, but that's what I have.

samba-lee · 9 Oct 2013

996 C4 exhaust silencer removal

Getting stuck in now.

I need to remove the silencers to eventually replace with something more interesting, but for now I am going to weld up the split seams and maybe do a quick bypass pipe conversion whilst they are off.

First problem is that the mounting hardware is very rusty and the long bolts look to have never been removed from new. I suppose it's a good sign as to the reliability, but as a result every bolt on the exhaust system is very rusty beyond any chance of undoing so they will all have to be cut off.

Most of the bolts are accessible, but the main silencer mounting ones aren't so I had to remove the longer mounting bolts. The long bolts sheared off so I tapped the remains up and managed to hacksaw the head off to push it down and out. Fitted a new long bolt in reverse (bottom up) for future access. The shorter mounting bolt towards the rear of the car is inaccessible this way so I will probably have to remove the rear bumper cover and heat shields, then use a Dremel or something to cut the head off.

More to follow...

samba-lee · 9 Oct 2013

996 exhaust tip polishing

Cleaned up my tips whilst I was in there. Even the tip mounting nut had to be cut off...

samba-lee · 12 Oct 2013

Exhaust mounting bolt removal

To get to the short exhaust silencer mounting bolt (to cut it off) I had to remove the rear bumper cover and side heat shield and frame.

All pretty straightforward, bumper was off in 15 mins. Side heat shield took a bit long as some of the fasteners were tight/rusty.

samba-lee · 12 Oct 2013

Managed to get a pad saw in through the silencer bracket and saw the remains of the nut off the short mounting bolt. Then push it up and saw the top head off the bolt. Then the silencer was free. Uncouple the cat connection (previously removed and new bolts added)

Also dremel'd though the tail pipe clamp bolt that was surprisingly hard.

All cleaned up, new stainless steel bolts put back on. That's one side done, although the cat to manifold joints need new bolts and gaskets...

samba-lee · 12 Oct 2013

996 silencer welding

Silencer is in a state, but i knew that. Looking towards a set of Dansk Sport so I wanted to get all the hardware undone first.

I won't be able to afford them for a while so I did a quick cleanup and snotty welding job on this silencer to keep me going over the next few months.

e8_pack · 12 Oct 2013

Great job, good progress. Where are you going to install the bypass? Does it give more power or just more noise, I remember a colleague of mine doing that.

samba-lee · 13 Oct 2013

Thanks. The bypass pipe goes between the inlet and outlet on the silencer hence literally bypassing the silencer. It's a bit of a hack really. There's less room on the 996 silencers than on the 993 ones I've done before, so I'll probably just wait for the Dansk boxes as mine are pretty knackered anyway.

I replaced the oil pressure sender today as I've been getting the "flicky" needle. It's a bit of a squeeze to get in there, but a 19mm crows foot spanner does the trick. New sender was about £42 from OPC

samba-lee · 21 Oct 2013

Finally managed to remove the CATs after much drilling with cobolt drills (needing to be reground every 30 seconds of drilling - literally). The remains of the studs in the CAT section were as hard as tool steel!

All just to put new gaskets between the CAT and manifold section.

Had to remove the air box to get access to the various sensor wires, but once in there it was a nice opportunity for a spring clean

and look around.

It's mainly just removing covers and various heat shields to get to the exhaust system. Collecting the gaskets and a few bits tomorrow from OPC then put it all back together hopefully until next year.

Shurv · 22 Oct 2013

Nice work, you're a braver man than me. :worship:

PeterS · 22 Oct 2013

It's good to see another one being resurrected.

I bet those silencer seams were spitting away as you were trying to weld them!

Good stuff.

:thumb:

Project WP0ZZZ99Z2S603158

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