Roxster Engine Tear Down - Porsche 986 Boxster track car build 5

[@davidgray5583]

New merch idea. Tee shirt with “ Yeah, that’s not good “ with your Roxster in the background.

[@sportflyer]

When you tell Mrs. Jeff that you need a bigger garage, can you please remember to video her reaction? 😁

[@stephenfrench4417]

personal protection equipment hard hat flak jacket etc may be required!!!

[@XiraArien]

@@stephenfrench4417 do not forget a bullhorn to keep at a safe distance

[@1one3_Racing]

I'm thinking Goonzquad style building

[@matsleight]

Know it doesn't get you further with the build, but really interesting content! Can't wait to see what happens to the Roxster next!

[@HomeBuiltByJeff]

More coming soon ;)

[@2BugsandaBack]

You could turn that scrap engine into a great coffee table with a glass top on it. Someone would pay a fair bit for it and that could fund the new engine.

[@andreasundesser1154]

And this table would already serve cappucino :D

[@harryfahrtdenwagenvor5202]

@@andreasundesser1154 with oily foam 🤣

[@mayhemmechanics4068]

No it’s only a shitboxter

[@Harryrcb]

The best way to get the head bolts off is with a full size air impact gun hthey will not come loose with a hand breaker bar. That btw is a good indication that the engine was overheated it freezes the head bolts

[@AlanGresham]

Good demonstration of a dual mass flywheel too.

[@stevegraham3817]

Words that should never be uttered... It's not worth buying new tools...

[@nazdagg2027]

how did the head bolts get so tight?

[@stevegraham3817]

@@nazdagg2027 modern vehicles use thread locking compound instead of spring washers, add in many heating and cooling cycles and they get tight. To put the thread lock compound in perspective, I couldn't loosen some bolts on my 4wd, took the car to the mechanic, onto the hoist, and this 140kg wall of muscle had to use a 6ft length of pipe on the end of the spanner. This was a man who has spent his whole life using 6ft long spanners, and even he was shocked at how tight it was.

[@maxcarter970]

That’s the second m96 I’ve seen torn down today. Wesley Kagan pulled his apart too but managed to get his head bolts off :)

[@jeffkopher3468]

My first thought too. Will stay very far away from these engines. Wesley has some cool projects as well.

[@bustedrusted7385]

you could weld nuts to the head bolts and remove with a standard impact socket if you really want it apart, or drill the heads of the bolts off

[@fredericrike5974]

Appreciate the second effort! Like several others, I watched Kagan take his apart earlier. Lost oil pressure seems to be going round for these. You had the "right " tools to be taking the head off- unless they were over tightened and maybe Loctited. Like maybe it has overheated before and the previous owner of the cheapest, sorriest Roxter in Oz did some repairs with JB Weld instead of gasket prep. Sorry for breaking your tools, though, you've worked hard to get the lot you have. I like the coffee table suggestion, or a boat anchor after all the oil is out of it. I wouldn't want to wish that mess on fish! PS; Don't buy anything else from this dude again, but I'm thinking you already knew that! Best to the Misses!

[@lieberfreialsgleich]

Great cars insourcing garage. Looks like my garage, Giulia, gt, boxster. In 32 years, I never had any engine problems, before I bought a Porsche. At 50000 mls , cylinders are worn, oval, washed out. And extremely expensive to rebuild.

[@garethjones2434]

Good job! Brave to go in with a hole saw, but good to see what the issue was.

[@DarrylSheather]

Have killed an RS200 Clio at Wakefield on turns 4 and 5, seized engines are always such a downer.

[@martinrodgers6114]

Don't know if you are into boating, but it would make a good anchor!

[@05magmn]

At 4:20 when you said there is sludge in here, that’s coolant in your oil!

[@bhrmotorsport6809]

Cutting torch for the head bolts.

[@ericl452]

You are probably correct about the engine overheating. However, the M96 and M97 engines very very rarely blow head gaskets (I want to say never). They do however crack heads. That is how they end up with intermix. Once there was enough water in the oil, it lost lubrication. The connecting rod bearings are the first to go.

[@danielprivate7442]

Thanks for the post-mortem.

[@alienpoker]

Thanks, Dr. Jeff. As expected the disease prognosis was terminal. (Usually the case post-mortem) The diagnosis: Disease was caused from the carelessness of the previous owner.

[@countryironforge4275]

Seems obvious with all that water in the block it was a massive coolant leak from somewhere, gasket or crack from overheating. Love it that you pulled it apart, totally unnecessary but we just have to try it right?

[@robertbills4290]

Glad you tried to find the thing that failed but like you said sometimes it's just not worth the time and money when you know it's scrap hopefully you can use some of the parts from it or at least weight it in for scrap Rob

[@oraziobarbagallo1609]

Don't know if you've seen Wesley Kagan on KZbin. He pulled a boxster engine apart as well, amongst the other wizardry he does.

[@richardhintonracing]

Oxy acetylene torch on the head of the bolt until it is cherry red it will expand and you will undo it . Also works on sheared wheel bolts the action of mig welding on a nut the heat frees the tightness and it unscrews . Keep a Co2 extinguisher handy.

[@playitlouder451]

AKA red and black spanner

[@trapjohnson]

Now it's a lovely paper weight.

[@alienpoker]

Or Boat Anchor, or Door stop...

[@hotdognr12323]

Very interesting to see! You could perhaps try to drill the heads of the head bolts as a last attempt?

[@HomeBuiltByJeff]

They are hardened steel bolts. It would take FOREVER. Just not enough reward for that amount of work required ;)

[@remcotissink]

Or a bit of heat ?

[@hotdognr12323]

@@HomeBuiltByJeff I see. I guess it's too much work just to confirm what we already know. Great idea using the hole saw by the way, I would never have thought of that!

[@dudeonbike800]

As stated previously, an angle grinder may make quick work of those bolts - assuming you're able to come in from the corners. If there are more that aren't accessible, then forget it. But drilling? No way.

[@mclarenjohnf1]

I notice in the USA some seem to like putting an LS in a Porsche, some say it works well some others say it is bloody noisy and it still blows from time to time with oil not staying in the right area through corners, I know that in you're neck of the woods you have pride in fitting a Barra in many things, but we also know that Jeff thinks outside the box, I have it a Subaru turbo with extra cooling and oil placement.

[@stuartd9741]

I'd say a Barra six thou not alot of room for one of those. A Subaru engine most likely. It's got to be able to punch out close to 600 horses to be porsche GT 2 spec...?

[@nigolt.4345]

Excellent Work!!! Keep it up!!!

[@johnnysmith863]

Another great vid, Jeff... though scary for me since I have a 986 Boxster outside. I hope you didn't make your 996 watch the autopsy!

[@HomeBuiltByJeff]

I have a mate who has been thrashing his base Boxster for years and he can't kill it ;)

[@bnambisan]

Time to start thinking about the next project Jeff...

[@celililkimen634]

You could heat the screws or boil out a screw that you could apply more torque. Anyway keep on going good content 😉👍

[@abdulkareemrainers3142]

I think that engine can still be used, some of it at least... all you need is a new block and internals for it🤔

[@pjvenda]

Such good news to see the teardown; Shame the head did not cooperate; Would the plastic bits be chain guides? Would the overtightening of the head studs mean something about the state of the engine? Also Jeff, would it not be possible to disassemble the engine from the other side, (provided the other head comes out) split the cases and remove the crank without removing that head [at the cost of a lot of effort]?

[@andrewgates4904]

Great video Jeff. Subscribed👍. Watching the projects with some envy.. if only I had the tools, big garage and pot of cash to do something fun to my Cayman 🤔

[@Fred82ndAbn]

Great video but I'll have to disagree with you on one small detail. If the sleeves and cams are good, you can refresh one of those M96 with new bearings, chains, tensioners, gasket sets and even the IMS (EPS roller version) for less than $2000 again, if everything else is good. I had a bad crank bearing (caught early enough thankfully) and did a refresh of the engine as stated. Everything was throughfully cleaned and inspected. For reference, in the US market, a good working engine is running in the $3-4K for a 2.5, higher stil if 2.7, 3.2, 3.4 or 3.6L so the economical logic is there. Thankfully all is well. Being running her hard for over 30K, so far no issues but I had to drill the head out of 1 of the head bolts. In your case, that engine seems was rode hard, hot and put away wet for a long time and definetely beyond help. Best of luck on your future projects. Cheers from Puerto Rico.

[@Euroburger]

Since the engine is totalled anyway and you're drilling holes into it, you could've sliced the headbolts with an angle grinder to take the head off. But as you said, you already know it's totalled. So why put in that much time into it, right?

[@dudeonbike800]

^^^ This! 15 minutes with an angle grinder would be TOTALLY worth it. Go Jeff, go!

[@HomeBuiltByJeff]

I though about that, but you cant get the angle grinder down to the bolts. I would have to spend an hour cutting the top of the cam tower apart to get to the top of the bolts ;)

[@dudeonbike800]

@@HomeBuiltByJeff Yeah, I get it. Plus, the cutting wheel would have been gummed up by all the aluminum before even reaching the steel bolts. Oh well, we armchair quarterbacks will think of some other way you should waste your time! Ha, ha! Thanks for the video and reply!

[@Talasas]

Dying to know what engine you have planned. Turbo M96? LS? Coyote conversion? 🤔

[@grumpyoldman6632]

Please not an m96 or mezger, id love to see an LS or something else

[@eddyagg]

Surely there’s a porsche guy on here that could lend the right tools or go to his joint and do a video with him pulling it apart 👍

[@davidjw14]

If you haven't already seen it Wesley Kagan's tear down of his Boxster engine on KZbin is worth a look. The bearing failure is quite spectacular

[@HomeBuiltByJeff]

Mine was worse ;)

[@davidjw14]

Agreed. But the difference between the two is only a matter of time and use.

[@darbecengineering8087]

can you not reach in with the plasma cutter and just whip the heads off the bolts? Might damage the head itself in the process but if its for scrap anyway :)

[@stuartd9741]

Ah, but that's cheating 🙂 Thou I guess using a whole cutter in the block cheating also lol. Sometimes it's the challenge but also where you learn alot using scrap parts. (About techniques to remove stubborn bolts)

[@PerformaIT]

Great video Jeff - please show us a vid of removing the clutch & dual mass flywheel so we can see the IMS bearing behind it. Then we can all put our minds to rest that wasn't the cause! :-)

[@HomeBuiltByJeff]

The chains were tight so it definitely wasn't the IMS

[@imouse3246]

Thanks for trying to humour us Jeff. Good try none the less. √ Have you considered some C-4 to get that head off? 😁

[@1one3_Racing]

The fact those head bolts are too tight leads me to think its had a bad rebuild. Initially I thought head gasket too but with that broken conrod its possible it punched into a water gallery which is why theres water in the exhaust. Hard to say what happened first.

[@stephenfrench4417]

Make a coffee table or even night stand out of the hulk. Spray it red and add some nice hard wood top

[@bentandre5524]

it will be a very effective presse papier

[@_zzpza]

Drill the head's off the bolts maybe? Either way, yeah don't waste any more tools trying to get the head off.

[@markwalton8644]

I had a feeling with that much water it'd be the water /oil cooler night be passing. Jeff have you thought about maybe an Audi V6 conversion or a EG33 conversion???

[@cedriclason9436]

Nice try Jeff but we are not going to let it go so easily 😊 I bet we'll see you in a next video drilling the head bolts heads out and exposing the piston-rod mess.

[@HomeBuiltByJeff]

Nope. That is a crazy amount of work. I am happy to say it is dead and move on with my life ;)

[@JohnKaufmann]

Torch

[@anthonyvanuden6101]

Yup should turn the Boxster into an electric vehicle that would make a good watch

[@clivewilliams1406]

As the engine is toast anyway, why not drill the heads off the torx (or splined bolts??) and then the heads can be removed? Even if the engine was to be rebuilt this course of action was still viable as it would have been easier to remove the last vestiges of the bolts when the heads were out of the way.

[@neilmchardy9061]

Well that’s knackered that.

[@nippy2013]

Drill the bolts?

[@nickmassey9104]

Well at least you're 90% sure of the cause ..a few usuable parts left for other Porsche boxster owners there Sat on my wall outside watching with a brew .I'm supposed to be washing the cars 😃

[@florasdad1]

Can you weld on a bar to the nut?

[@HomeBuiltByJeff]

That would have been something to try, but in my experience the welds still seem to snap first.

[@florasdad1]

Did look pretty tight

[@orionflyer56]

Just try heating it up first.

[@gregh7457]

the heads are worth something or at the very least core value

[@haveric24]

that water in the sump says it all now build that turbo 3.2 and get out the track, make the roxter a trackstar

[@honestpat7789]

Has the Alfa got a new sealing coat applied, or is the lighting making it look matte black?

[@benhowe2087]

You could drill off the bolt heads. But you will probably loose a few drills in the process.

[@timosariwating8655]

Don't you worry about fluids and junk getting on Harry when you park it under another car on the lift like that?

[@dudeonbike800]

Exactly my thoughts! I'd NEVER put that POS over anything I valued!!!

[@HomeBuiltByJeff]

There are no more fluids to leak :D

[@cristianmistretta7826]

Well, it's a pity for the engine, but i'm excited for what it's next. Is the plan maybe a big Lambo engine?

[@andheeid]

you should heat the area near the bolt first to make it easy to open

[@orionflyer56]

That's the first thing I thought of after the tool broke. Start with propane then Mapp gas then acetylene. Or maybe weld a nut to it.

[@stevenwest1494]

Haha, my Alfa 156 died a similar death, but it got me home 6 miles with big end bearing jangling around. Bad luck on destroying your torque! It's annoyingly expensive to get 2 good new ones!

[@TheBuildRoom]

You can't have too big a garage or enough tools.... 🚘🚘🚘🚘🏠

[@rpeterson223]

IMS bearing grenade that compounded

[@HomeBuiltByJeff]

Nope

[@Encom0]

One way of adding lightness I guess :)

[@Thomamps]

Time for "if it's liquid it's loose" meme

[@garynorman5179]

Thought you would have taken off the clutch and just checked the IMS out of interest?

[@HomeBuiltByJeff]

That is a good point. I might pull it just to see the condition.

[@STB-1]

@@HomeBuiltByJeff to get your head bolts loose simply use a punch inside the head of the bolt or just the top off the bolt and give it a couple of hits with a nice heavy hammer, you will never have to buy another Torx bit due to twisting or breaking the end off.

[@dudeonbike800]

Yikes! Seeing the Roxster above Harry makes me VERY nervous!!! Couldn't it vomit parts or fluids at the drop of a hat for no reason?

[@devakumaransatchithanathan4795]

#YeahThatsNotGood #TrademarkByJeff 😂😂

[@danielhughes9556]

If it ain't too late, torch the head bolts off with a oxy acetylene torch. If its possible. Inquiring minds want to know!!!

[@julianstarkey9301]

Subaru 6 Cylinder would be too obvious and done before, albeit in 911. VTEC would be novel.

[@stuartd9741]

Barra six or an BM M3 straight six? Yeah have to completely rebuild the body afterwards.?

[@tabberacci8541]

Where’s part 4?

[@pascaljeske7307]

Wow this Looks not very good but nice Video Jeff ❤️👍👍👍❤️

[@mayhemmechanics4068]

Its bitch of a job it is to get the gudgeon pin and retaining clips in to the other side of the engine Did a boxter last week You have to Line up the rod and piston perfectly hope the rod doesn’t jump The slowly feed the pin through the entire block on a long ass tube hope it fits nicely then do the same with the clip only wishing that it doesn’t ping of again and get lost in the crank case😢 If it does, the yeet the engine of the stand and send your self abroad for a nice vacation 😮 (nice little tip for mechanics if you fuck up)

[@gjmob]

The cylinder wall has cracked and water has come out of the water jacket

[@andreasundesser1154]

corvette engine incoming?

[@FredrikFridsten]

Oh no! You're taking the engine from Archie... :D

[@thedpascal]

This is: " une bielle de coulée".

[@jubiletabustamanteserrano2446]

ME GUSTAN MUCHO LOS VIDEOS QUE EDITAS , PERO HABLAS DEMASIADO TIEMPO EN LA EDICION DEL VIDEO

[@paulwhite7475]

Time to swap an LS into a boxter 🤣

[@300DBenz]

Hmmmmm.......new engine time......... How about an LS swap, have the engine stick out the back of the car, just like those old Volkswagen Beetle dune buggies.

[@grumpyoldman6632]

Please not an m96 or mezger, id love to see an LS or something else

[@richieduck67]

Please get an engine stand

[@HomeBuiltByJeff]

I have 2, but to you need the correct yoke for the M96 engine. Universal ones are no good ;)

[@HappyDaysNI]

That was funny.

[@tx5brent]

100% that spun a bearing due to a head gasket

[@timwhalan6417]

👍🏻🍺

[@thescottishhammer7570]

#LSSWAPTHEWORLD

[@CChallinor]

Edd China could get that running,...

[@kiwihame]

If you need some Boxster engine teardown catharsis Jeff, just yesterday I was watching Wesley Kagan, another very clever bloke, tear down his "Knockster" M96 engine. Same issue as yours, just didn't get as far. Here you go. kzbin.info/www/bejne/fYuqk3puh9Gko68

[@grantgrant77]

Whaaaaattttt???? I was gonna buy that engine from you... now it has a hole. If you had it on an engine stand you coulda got those heads off. Oh noooo.....

[@philiphill9400]

Broken !!

[@Ride2Xplore]

Please strip the body of these hideous modifications!

[@HomeBuiltByJeff]

But it looks so good :D

[@Ride2Xplore]

@@HomeBuiltByJeff lol!

[@garethmayfield4014]

thats definitely not good fella

[@milanbauer4226]

Poor engine.