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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 700
Location: S.London


PostPosted: Sun Oct 05, 2014 5:36 pm    Post subject: Reply with quote

I think you jinxed my car!

Just finished fitting my new sill cover after spending 2 hours removing the bloody tape from the old one and decided to check that I hadn't flattened the battery, start the car and it sounded 20 times louder than ever along with a metallic noise... Slightly worried, I got on the floor and spotted a gasket hanging down from in between the downpipe and cat.. With that not being the catastrophic failure I thought it originally was, I decided to go around the block to have a taste of a slightly amplified "gundo" hack.. Once warmed up, I opened it up, wow, it sounded insane! I did a fly by past a friends house who thought I was driving some sort of race car Smile

So now, collect all the new exhaust fixings and get the boxes gundo'd!
Another good shout on the heatsheilds, mine are a bit crusty!

Have you done the oil tandem pp by any chance?
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 700
Location: S.London


PostPosted: Sun Oct 05, 2014 6:09 pm    Post subject: Reply with quote

Are stainless bolt/clamp kits available online?
 
  
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Frenchmeister
Barcelona


Joined: 24 Feb 2014
Posts: 1328
Location: Beautiful Cumbria.

2004 Porsche 997 Carrera 2S

PostPosted: Sun Oct 05, 2014 7:23 pm    Post subject: Reply with quote

Mark, Clamps available from the main dealers which are circa £19 each, these are the long sleeve clamps about 75mm long they come with bolts.
Check E Bay or a local engineering suppliers for stainless bolts, you want some M8 X 30 and M8 x 40 get some washers and spring washers.
Yes i have done the tandem pump.
You can PM your phone number if you wish and i can tell you about it, DIY job but bloody fiddly considering it is only 4 bolts.
Done nothing on mine this weekend apart from plug it into the C Tek, i have a new serpentine belt and oil and filter to change.
Cheers Jim.
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997 Carrera 2S 54 Arctic Silver
944 Turbo S 88 Solid Black
BMW X3 2.0D M Sport 06 Silver Grey
BMW E46 330i touring M Sport 05 Imola Red 2
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 700
Location: S.London


PostPosted: Fri Oct 10, 2014 11:06 am    Post subject: Reply with quote

Thanks again Jim!

I have ordered a pile of new bits! Stainless bolts, washers and nuts for the exhaust, new clamps, gaskets and stainless heatsheild bolts. Hoping to pop into OPC Byfleet tomorrow to order new heatshields, fuse box cover lid as mine has scuffs, fresh bolts/screws for arch liners and trim.. Want to price up new inner arch liners too as mine are a bit pebble dashed and tired..

I checked out my tandem pump and it looks and feels unharmed at the moment so I won't be changing that just yet, I will give it some form of protection though to prolong it's life from rust! I'll bare in mind your offer of help when the time comes, thanks!

Get some pics of yours up!

Not done anything with mine this week, it has sat under it's cover all week. Sad
 
  
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Porschekit
Österreich


Joined: 12 Aug 2014
Posts: 915
Location: North East UK


PostPosted: Fri Oct 10, 2014 12:46 pm    Post subject: Reply with quote

Mark,

Absolutely brilliant thread of information and pics Thumb well done !
I know where to come when I need to fettle my 997.1 , thanks.

John
 
  
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Frenchmeister
Barcelona


Joined: 24 Feb 2014
Posts: 1328
Location: Beautiful Cumbria.

2004 Porsche 997 Carrera 2S

PostPosted: Fri Oct 10, 2014 7:05 pm    Post subject: Reply with quote

Need to sort some pics out Mark, i will get it sorted, how do we post them ? as the PCGB forum is a nightmare to post pics on.
Stick your liner screws in a bit of cardboard after rubbing them down and give them a coat of satin black, that said new ones will be coppers !
Tight Norfern Git Laughing
_________________
997 Carrera 2S 54 Arctic Silver
944 Turbo S 88 Solid Black
BMW X3 2.0D M Sport 06 Silver Grey
BMW E46 330i touring M Sport 05 Imola Red 2
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 700
Location: S.London


PostPosted: Sun Oct 12, 2014 10:08 pm    Post subject: Reply with quote

Thanks John!

Sort it out Jim Wink

Spent a fair few hours this weekend making a start on sorting out the broken exhaust joint.. Took a bit longer than planned but that was down to just working out what comes off where and how..

The start






The failure! Can't believe the nuts have totally disappeared..




Spotted the same on a clamp










I spent ages getting the clamps off which hold the cats in place and called it a night..

Today, I spent ages attempting to drill out the stuck bolts... After blunting many drills bits and finally getting one of the "studs" smoking hot, it just fell out!! I then realised that I had been trying to drill studs out so, out came the mallet and with a few good wacks, they just popped out!







I now have my stainless bolts to replace all this but I am waiting on the rest of the goodies to come, clamps, gaskets etc..

A crude pic of the freshly painted tandem pump to help prolong it's life..



Lastly, some freshly coated cats, only high temp paint to tidy them up as rust is not a good look!!
 
  
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911UK
Porsche Community
Porsche Community


Joined: 15 May 2002
Posts: 10077
Location: 911UK

1997 Porsche 993 Carrera 2

PostPosted: Wed Oct 15, 2014 2:05 pm    Post subject: Reply with quote

Thumb


<mod update, thread moved into 997 forum > Thumb
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jjppww
Trainee


Joined: 23 Nov 2013
Posts: 74



PostPosted: Wed Oct 15, 2014 5:32 pm    Post subject: Reply with quote

911UK wrote:
Thumb


<mod update, thread moved into 997 forum > Thumb

Where?
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2006 C2 Hartech Re-build
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 700
Location: S.London


PostPosted: Sat Oct 18, 2014 4:11 pm    Post subject: Reply with quote

Ohh I've been moved here.

Not too much has happened this week as I have just been waiting on parts. I used www.deroure.co.uk to order my new Porsche parts as I couldn't make any time to get down to my nearest OPC. They willl arrive on Monday I believe. I also get my backboxes returned to me on Monday courtesy of my friend who is welding in a 1,75" bypass pipe.

Using a Porsche parts catalog, I managed to find out the correct nut/bolt size of all the nuts/bolts that usually rust away, I hope this will stop any future grief of bolts snapping and getting stuck. Also, rather than buy the 2 main clamps which hold the backboxes to the cats from Porsche, I decided to refurb my ones. The main body of the clamps are solid and do not appear to rust, it is simply the nut and bolts that do so it was pointless to replace the clamp. I simply tapped out the remains of the coach bolt, had a friend cerakote the clamps and I refitted the clamps with stainless coach bolts and serrated nuts.





Just incase anyone wants to replace their nuts/bolts, here is a list of what you need.

Exhaust clamp
Coachbolt M8x25
M8 serrated nut

Coilpacks
12 x M6x25 part threaded

Coilpack heatsheilds
2 x M6x10

Backbox fixing to hanger
2 x M8x140 part threaded
2 x M8X70 part threaded
4 X M8 nuts

Backbox bracket to backbox
6 x M8 nuts

Cat - backbox flange
6 x M8x30
6 x M8 nuts
6 x stainless split washers

I'm sure I have missed something..

That's all for now.
 
  
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Frenchmeister
Barcelona


Joined: 24 Feb 2014
Posts: 1328
Location: Beautiful Cumbria.

2004 Porsche 997 Carrera 2S

PostPosted: Sun Oct 19, 2014 8:41 pm    Post subject: Reply with quote

Told you the fixings were sugar ! when refitting place the long exhaust hanger bolts in from the bottom rather than the top as further removal is easier as the bolts will not come out as they hit the chassis.
meant to change my oil but mates ramp at the garage was busy, probably next week now, i will also be fitting springs over the next couple of months.
What do you use for removal of tar under the arches ?
_________________
997 Carrera 2S 54 Arctic Silver
944 Turbo S 88 Solid Black
BMW X3 2.0D M Sport 06 Silver Grey
BMW E46 330i touring M Sport 05 Imola Red 2
 
  
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a1topdog
Monza


Joined: 02 Mar 2005
Posts: 212



PostPosted: Mon Oct 20, 2014 9:20 am    Post subject: Reply with quote

Great thread. I need to started replacing these nuts / bolts on mine.

Which supplier have you used for the stainless nuts / bolts?
 
  
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steve baker
Nürburgring


Joined: 15 Nov 2011
Posts: 398
Location: Essex, UK

2007 Porsche 997 Turbo

PostPosted: Mon Oct 20, 2014 4:08 pm    Post subject: Reply with quote

Frenchmeister wrote:
What do you use for removal of tar under the arches ?


Autosmart Tardis Thumb
 
  
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Chris_in_the_UK
Estoril


Joined: 19 Mar 2014
Posts: 3579
Location: Harrogate


PostPosted: Mon Oct 20, 2014 5:38 pm    Post subject: Reply with quote

This, Autoglym Tar and Glue remover is pretty good as well.

steve baker wrote:
Frenchmeister wrote:
What do you use for removal of tar under the arches ?


Autosmart Tardis Thumb

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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 700
Location: S.London


PostPosted: Tue Oct 21, 2014 10:06 am    Post subject: Reply with quote

Good shout on reverse fitting the nut/bolts. I actually tried to undo one of these before I discovered the 3 nuts and did find I ran into a brick wall, reverse fitting would get around that! Wink

I did use Autosmart Tardis to remove the tar, I don't think there is a better product. I have also used Valet Pro Dragons Breath, this removes stuff which Tardis doesn't. (Iron fall out). I really recommend that stuff.

The stainless nuts and bolts were all bought from a local independent DIY store which has saved my life many times. Smile


PC
 
  
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Riccardo
Silverstone


Joined: 25 Oct 2011
Posts: 100
Location: London


PostPosted: Tue Oct 21, 2014 11:53 am    Post subject: Reply with quote

Hi Mark,

Just read through your thread and wanted to thank you for taking the time to post it up. Very interesting read, I really enojy these progress threads, always makes me want to go and do something to my own car!

Keep up the updates!

Btw, where did you get the led sidelight bulbs? Any issues with the installation? I'm inclined to change mine as there is such a strong contrast with the Litronics.
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2006 997 C4S, Cobalt Blue
 
  
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MarkGolf
Hockenheim


Joined: 13 Nov 2012
Posts: 700
Location: S.London


PostPosted: Tue Oct 21, 2014 4:15 pm    Post subject: Reply with quote

Thanks Riccardo..

I got them from eBay, no idea where else sells LEDS nowadays. No issues what so ever, simple swap with the original bulbs which takes minutes.
 
  
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Ian Donkin
Monza


Joined: 21 Jun 2003
Posts: 246
Location: A Yorkshireman in Surrey


PostPosted: Wed Oct 22, 2014 10:26 pm    Post subject: Reply with quote

Any pics of your Gundo'd silencers Mark?

I'm also in Surrey (Byfleet is my local OPC) and I'm still weighing up whether to go down the Gundo route... Would be great to hear how you've got on Thumb
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'06 997.1 Carrera 3.6 - now traded :-(

Previously:
'04 996 Turbo
'94 993 Carrera
'93 964 Turbo 2
'88 G50 3.2 Carrera
'71 2.4T ('72 Model year)
'68 911L (The Wife's car)
 
  
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Riccardo
Silverstone


Joined: 25 Oct 2011
Posts: 100
Location: London


PostPosted: Thu Oct 23, 2014 9:35 am    Post subject: Reply with quote

Thanks for the response Mark, I'll have a look around at some stage.

Ian, I've also had the Gundo hack done to my own 997.1, went with the 1.5" pipe, had it done at "Styledynamics" in Hayes (£300 at the time, they even have a Buy it now on ebay).

I did it a year ago and have not looked back. Not once have I felt that it was too noisy or intrusive and at motorway speeds you don't really feel any difference (and thats driving at higher Continental speeds), while at lower speeds it sounds fantastic.

The only issue I have is that at very low revs, like when crawling along in traffic, I can hear what seems ever so slightly like a blowing exhaust. Not sure if this is applicable to all Gundos or just my specific case and would welcome feedback from other "Gundoers".

However, in short, do it!! Thumb
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krispe
Monza


Joined: 05 Feb 2014
Posts: 244
Location: Northampton


PostPosted: Thu Oct 23, 2014 3:26 pm    Post subject: Reply with quote

I have the Gundo hack installed by the dealer when I bought the car from as part of the purchase price. I therefore cannot compare it to a 'normal' exhaust as it is all I know. It does sound quite loud and even a bit rough at idle or when crawling with the windows open, (windows up inside the car it's actually quite quiet). The car sounds more like a race car at these speeds rather than a refined GT car and more people tend to look at the car. Everyone who has heard my car comments/compliments the noise and ask what exhaust it is? My Gundo hack uses 1.5" pipe. I quite like the fact that it really sounds like a Porsche when you start it up, (if that makes sense?)
 
  
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