Turbo 3.8L Cayman Engine Build (Porsche M96) - Part 7

[@artmchugh5644]

Thought you were holding a cylinder sleeve !! Then I saw the coffee cup !!!!😎😎😎😎😎😎😄😄😄😄🍺🍺

[@BoostBrothersGarage]

Haha, would have been a way different video if I was holding a sleeve!

[@anthonyromano90]

Videos like this show us why these engines are so expensive to rebuild. I think you are looking at the right things. Check to make sure the tools slide fully through. Maybe try a dry fit of the tool without the piston to make sure it fully clears the sleeve. Then check if it fully fits into that piston before assembly. Maybe that shoulder is slightly undersized and doesn't let you get to the second groove. Thanks for showing how many tries these things can take. Let's us all know it is not just us! Stay safe

[@BoostBrothersGarage]

The tool does properly fit the piston, and the tools do fit through the sleeves. I think the tool just isn’t sitting flush in the first groove once everything is bolted together. I’m going to do some digging today!

[@TrentonBills]

This is such a good series, watching you overcome this engine and seeing your sanity slip away😂

[@terrylessmann2274]

Your diagnosis seems logical. Best of luck. Third time's a charm. We are learning vicariously thru you.

[@BoostBrothersGarage]

Thanks Terry!

[@StevenHasson]

Let me say this,... Yes it must suck and we all experienced something that needed to be done and was hell to do, but over here in RI deep in Corvid-ID 19 hell - I completely appreciate all that you are doing you are helping me in these times, teaching/informing me and I support your channel and all that you do - thanks!!! Keep it real that what makes me coming back

[@BoostBrothersGarage]

Thanks Steven, appreciate it!

[@gnrrpreacher]

Well, I chuckled at the irony of the lead in advertisement. It was for Master Class and it was about this guy being taught "Don't be afraid to suck" by Aerosmith. I watched the ad then you go all negative in the beginning of the video. I chuckled. It sucks you are having issues with this, but we are right there with you brother. Mike, hope you and the family are staying safe.

[@BoostBrothersGarage]

Lol, truth in advertising!

[@RebuildRex]

Thank you for sharing! I always learn a lot from your videos. In the case of this video, I learned that I probably don’t want to build a Porsche Cayman engine! 😬

[@BoostBrothersGarage]

Lol, I actually made a pretty fundamental mistake that I am just now realizing. I think (maybe I should stop doing that lol) that I will be able to do it successfully moving forward.

[@chadlegault9993]

Yes, thank you for posting as a video :) Much appreciated. I bet there are hundreds of us with 944's sitting on the decision to buy a Cayman but are stung buy the Porsche pricing and not sure about the flat 6. So appreciate your persistence with this build. Stay safe too eh.

[@BoostBrothersGarage]

That’s the thing, it’s such an incredible platform and the price is almost too good to pass up. Being able to do DIY engine builds will make or break these as a budget enthusiast car. Well that and more swap options, like an 07K!

[@Mustang_Chris]

@@BoostBrothersGarage I really like the idea of using the Ford Cyclone 3.7 originally designed by Porsche and Cosworth. Cams, head work, and ported intakes are available and can give nearly 500 hp N/A like the 911R.

[@paulhoffman1481]

@@BoostBrothersGarage thats awesome love how you guys show us how to do the hard parts and figuring all this out! You can afford to do stuff thats so much cooler if you can do the labour yourself! It will be cool to see how this car will compare to the 944 on the track! Also i have been collecting more parts for the 944 07k swap and had a few questions, i previously asked you about the lambo header and you said to get the left side, by that do you mean drivers side header? And as for the turbo do i want an hx35 or hx35w? If im changing the exhaust housing would it even matter? Also could you get me the link for the exhaust housing you put on your hx35? Im a noob to all of this but im trying to learn as much as possible lol. Thanks!

[@BoostBrothersGarage]

@@paulhoffman1481 Header part number is 07L253034A. The W on the HX35 just means it has an internal wastegate, which won't matter when you replace the housing. Link here: www.amazon.com/Turbo-Lab-America-Turbine-Housing/dp/B07GZ3WVS5

[@paulhoffman1481]

@@BoostBrothersGarage great thanks!

[@grantgrant77]

Thanks for the video. I may be rebuilding my M97 soon, so I’m very interested in your building videos. Please keep us posted on everything including your issues. Good luck 👍🏼

[@BoostBrothersGarage]

Will do, thanks!

[@fishadthethird]

If you need some tips and tricks for engine assembly you can hmu.. I rebuild one of those engines just recently. I can relate to your struggles with installing pistons 4-6 as I had some difficulties with them as well. I spoke to a Porsche Tech (I'm German btw.) and one of his tips was to use extra thick grease when installing the connecting rod bearings onto the crankshaft to reduce movement so that the connecting rods stay put while you install pistons 4-6. I know that tip is a little late, but hey.. maybe next time you can use it. Another trick which might help would be to flip the entire engine assembly by 180 degree, so that cylinder bank number 2 is facing downward and working with gravity rather than against it. If the engine is flipped that way you will have better time to install the pistons, since the connecting rods stay put facing downwards. Now you just need to align them (you can feel it when the shallow tool is seated all the way or you can make some markings on the tool itself and the case so you know when its properly seated (you have to do this for each cylinder individually obviously).. Then slowly(!) guide the punshing tool through the hole of the shallow tool and just before you hit it (you can do a marking here as well if you feel like you need it) punsh it nice and hard once. If you didn't succeed, don't proceed trying to get the wrist pin to fit, it's probably not going to happen. Just accept it and start over, eventhough I know how much it sucks. If you need any more tips for installing the pistons or when installing the cylinder head, camshaft timing,.. you can hmu on instagram (checking more often than here on youtube): xvictor.pf Hope it helps and stay safe! :)

[@BoostBrothersGarage]

Thanks for the pointers! I actually got pistons 4/5/6 installed last night. I ended up having to file down the end of the tool down so that it more easily engaged the piston properly. From there it was smooth sailing!

[@fishadthethird]

Boost Brothers Garage Glad to know that you were able to get it done! If I recall correctly I had to modify the tools as well to make them fit properly! Keep up the great content!

[@weldchip]

@@BoostBrothersGarage i was going to say i have never had a problem like that its always been pretty plain sailing, there are even some Porsche factory engine assembly videos floating around somewhere and they just sail through. I'm guessing its either the od of the hole in the after market pistons or your tool. looks like filing the tool down slightly was a good solution. one day down the road your build another Porsche motor and it will be easy second time :-) Keep plugging away, we have all been there just like you late at night with the sinking fed up sick in the belly feeling when something hasn't gone to plan or we broke something expensive. your not out there on your own brother :-)

[@kluupom]

Keep up the good work! I hope it will fit the next time👍🏼 Greetings from Germany 🇩🇪

[@BoostBrothersGarage]

Next time will be a success!

[@Russell_and_Rosko]

10% like to view ratio atm. You’ve got a ton of support 🤘🏼

[@BoostBrothersGarage]

I’ll take all the support I can get!

[@davidcantrell5098]

Is there no way to fish that circlip out the hole? There's no ridge holding it in. There looks to be a gap (oil hole or something) in the shoulder where you could slip a small hook behind it and pull the circlip out of the piston. A length of stiff wire with a small hook might get to it. Also a telescoping magnet pickup tool in the hole at the same time to catch the circlip would be a must.

[@frankleonard6291]

I love it, real issue, keep your head up

[@BoostBrothersGarage]

Will do, thanks man

[@djambrosia]

Shame you can't dry run before putting the case halves together. Respect for not already setting fire to it!

[@BoostBrothersGarage]

The thought has crossed my mind lol

[@jkinerk]

This was informative and interesting, was there any chance though that your new found perspective was influenced by what's in your Yeti there? Asking for a friend.

[@BoostBrothersGarage]

Hahahahaha, nope, it was Diet Coke. Maybe the first night of quarantine that I didn’t drink.

[@toroTalks]

Can you insert the tube in without the circlip and see if it's seeded all the way with your scope? Just an idea. Never done this before

[@BoostBrothersGarage]

That’s the solution I came up with as well, although I haven’t tried it yet!

[@dgpgarage9291]

I sad of the lack of Miller light in this video, I think that’s the problem 😉

[@BoostBrothersGarage]

Lol, my son was sick and my wife was worried we would have to go to the Dr, otherwise I would have been double fisting. He’s good though. Hope you and your family are well!

[@dgpgarage9291]

Boost Brothers Garage ahaha, you too man!!! Stay safe!

[@MowSow]

What was the rebuild company that didn’t line up the sleeves holes properly so I don’t use them 😀😂

[@BoostBrothersGarage]

Motormeister, luckily they are long out of business!

[@kerryL]

oof... you'll be able to build this in your sleep next time you put it back together

[@BoostBrothersGarage]

It is definitely getting easier with every rep haha

[@elliotwong8416]

i would say the circlip is a sucks idea LOL

[@ROYALUSTER]

Sorry man....That sucks!