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Discussion Starter #141

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Good progress Nick. When you put the engine back together I would treat it to a new oil cooler since it might not be possible to get all the bits out of the old one.

Good luck,

Rob
 

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Discussion Starter #144
Here are the latest videos

engine rebuild 12
https://www.youtube.com/watch?v=83pacLf3pQc

engine rebuild 13
https://www.youtube.com/watch?v=1NKaz3heMP8

engine rebuild 14
https://www.youtube.com/watch?v=0jUbOdUQOeo

engine rebuild 15
https://www.youtube.com/watch?v=SyhV3K4VtNU

engine rebuild 16
https://www.youtube.com/watch?v=EBMTjpupBO4

engine rebuild 17
https://www.youtube.com/watch?v=aXBJ63_mPb0

engine rebuild 18
https://www.youtube.com/watch?v=2YVZk4wMBe0

engine rebuild 19
https://www.youtube.com/watch?v=d-VXkkXR_8o


Intake and exhaust camshafts on both banks looked OK.
Hydraulic lifters looked OK.
Heads looked OK.
Cylinder walls and pistons look OK (from top).

bank 1-3


bank 4-6 some very minor scuffing but hardly enough to grab finger nail


so now I have to work on taking apart the engine block itself. Maybe one of the bearings in here got damaged and is what caused the metal pieces.
 

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Discussion Starter #145
Hi Guys,

So here is the latest.

engine rebuild 20
https://www.youtube.com/watch?v=37I12-gT1AM

engine rebuild 21
https://www.youtube.com/watch?v=WrtTp9jVu7c

engine rebuild 22
https://www.youtube.com/watch?v=iMiHlor7t_A

engine rebuild 23
https://www.youtube.com/watch?v=7jx6UdP_KF0

engine rebuild 24
https://www.youtube.com/watch?v=KPAyqdDMIio

engine rebuild 25 (this one shows an overview of damage)
https://www.youtube.com/watch?v=l0MtjdCfEzE

and pictures










































So let me know what your thoughts are. I would like to know what you guys think caused this. I think it may have been the cold start and having no oil by-pass. Also, is this damage too extensive and need new pistons and re-sleeve, or OK to re-assemble with just new bearings?

For comparison. This is what I did the first time;
 

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Nick
I was wondering if you reused the oil cooler and it had junk in it from first upset. I would show your pictures to LN to get their opinion. My feeling is you need to get rid of all scored pieces or you will be burning oil. I don't recall but did you crank engine with no fuel to get oil flowing?

Good luck

Rob
 

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Jake Raby (Flat6 Innovations) sees quite a few engines that have failed in cold environs. I won't speculate to the cause but you may want to include him on your emails with LN and search Rennlist with what he has to say about it.
 

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Nick
I was wondering if you reused the oil cooler and it had junk in it from first upset. I would show your pictures to LN to get their opinion. My feeling is you need to get rid of all scored pieces or you will be burning oil. I don't recall but did you crank engine with no fuel to get oil flowing?

Good luck

Rob
This is exactly what happened here. Nick was in communication with Jake and yes, he admitted to reusing the oil cooler after the original failure when the cooler should have been replaced. This same phenomenon has been occuring for years even in aircooled cars - engine fails, is rebuilt, and oil cooler lines and cooler aren't pulled and replaced.There are literally tens of thousands of spin on filter adapters used in M96, M97, and 9A1. Also, every Flat 6 Innovations engine comes with one, even those used on the track. Lack of a bypass is not the issue here. If anything, the spin on oil filter adapter limited the amount of collateral damage since it has no bypass.

This kind of damage can also occur when an engine is run with broken rings. There are other things that can also lead to system wide damage like this, including, but not limited to, improper cleaning of the bores as the honing oil is mixed with nikasil dust and is liquid death.
 

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Discussion Starter #149
Hello Everyone!

Thought I would finally give an update on this whole project of mine. I ended up completely taking apart the engine again in 2016 and reassembled it at the end of 2016. I didn't want to call it a success until I had at least 10,000km on the new-new rebuild. This summer I drove out to British Columbia (from Saskatchewan) and back and I now have about 12,000km on my 2nd rebuild! So I think I can call it a success now.

I re-used the same block and pistons. They had very slight scuffing from the oil issue on my first rebuild. I put 5,000km on and had it go down 2 segments on the oil level. So 0.8 litres of oil consumption which I think is normal.

I took videos of the whole rebuild process. Its 70 videos that are all about 20 minutes long. When I get a chance, I am going to upload them.

That's all I have for now (until I upload the 70 odd videos). Felt like I was leaving you guys hanging by never posting what happened. As a lot of you were a super big help!

Cheers,
Nick

 

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Hello Everyone!

Thought I would finally give an update on this whole project of mine. I ended up completely taking apart the engine again in 2016 and reassembled it at the end of 2016. I didn't want to call it a success until I had at least 10,000km on the new-new rebuild. This summer I drove out to British Columbia (from Saskatchewan) and back and I now have about 12,000km on my 2nd rebuild! So I think I can call it a success now.

I re-used the same block and pistons. They had very slight scuffing from the oil issue on my first rebuild. I put 5,000km on and had it go down 2 segments on the oil level. So 0.8 litres of oil consumption which I think is normal.

I took videos of the whole rebuild process. Its 70 videos that are all about 20 minutes long. When I get a chance, I am going to upload them.

That's all I have for now (until I upload the 70 odd videos). Felt like I was leaving you guys hanging by never posting what happened. As a lot of you were a super big help!

Cheers,
Nick

Glad to see you got it back together and going again. Here's too many miles of happy motoring:cheers:
 

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Terrific news! Maybe post the videos to YouTube and insert links to them here. I foresee binge watching in my future...

Sent from my XT1650 using Tapatalk
 

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Discussion Starter #155 (Edited)
So here it is! The Playlist of all 68 videos. From crank assembly to mounting transmission.

It might not be the greatest of videos, I block the view sometimes. But if someone is interested in doing something similar, they can see all the steps I went through.

All 68 videos in a playlist. I gave my internet a workout this weekend.

This is the link to playlist. Doesn't seem to work when viewing on mobile though.
https://www.youtube.com/playlist?list=PL75whMNCPXyvgTvXFEKaS6vA1Tzha0G2c

First 3 videos


 

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I came late to this party! Got my Boxster couple of years ago and just saw this thread today. I spent most of the day reading and watching all the the postings.

The only thing I can say is WOW!!!!!!!!!! JUST WOW!!!!!!!!!!

I absolutely admire your dedication, persistence and bravery! I have done some pretty crazy stuff in my life, but you are my hero!

Did you come to a final conclusion of what caused the second failure?

Thank you for all of your hard work and posting all of this. Huge benefit and great learning for me and I think for all of us.

Good luck!
 

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Great thread, and posts. Outstanding you had the courage to tackle this solo and then document. You ever make it to Houston, I will buy you a beer, or 20.

Thank you!
 

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I have never rebuilt an engine and had ideas that I might do it someday, but I might just limit that to an LSX if I ever go there. Now, I am sure I would not try my hand at rebuilding a newer Porsche engine after looking at the costs and estimating how much money I could generate working with all of the time it would take instead. I was looking on BGB's site at 3.8l conversions a few days ago and thought it was a good deal, but now I know it is a great deal since I don't have to anything beyond drop off, pay, and pick up. This absolutely epic thread was the voice of reason for me. I am thrilled to see it all worked out in the end, you gained an experience that you will never forget as long as you are of sound mind and what an incredibly generous contribution to this community from someone who would not appear to be a likely source for this type of thing, but no Porsche rebuilding for me, none. guglido, you definitely have no shortage of courage and resilience. See sig line...
 

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I have read the entire thread from post 1 till now in one sitting. My jaw dropped to the floor when you found metal shavings in the oil after putting it all back together! I imagine the level of mental tension behind all of this. Big thanks for your documentation and good luck!
 
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