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Porsche 9165 Tool - Some clarifications on making your own
For the folks that have been here for a long time, or working on these cars for a long time, this is an old topic, but I thought I'd put up a new thread with some things I wanted to clarify, and give it a more search-friendly title.
I hit the dreaded wall of the dust caps on the front spindles. I don't think my car was ever near the Salton Sea (Thanks for that phrase go to @GregBBRD ) but it did come from the midwest, which I think must be similar, at least in the winter. Anyway, it was really, really difficult to get my dust caps off. I tried using a bit of wood, wedged in the groove (no dice), hitting them directly with a rubber mallet (no dice), and the muffler hanger contraption (also no dice). Hmmm, back to the drawing board. Here's the threads that I followed for some of those tips and ideas:
That was totally the ticket, but some of the information was not quite right so I wanted to set things straight and maybe give a little more of a DIY procedure for those inclined to make their own version.
Most importantly, you only need a 2 inch reducing coupler. The one that I found at the local home store was a 2 inch to 1.5 inch reducing coupler. I also bought a 1.5 inch bushing, to further reduce the pipe size I needed to 0.75 inch. Here's what that looks like: That last post indicates the use of a 2.5 inch reducing coupler and those things look to be rare as hen's teeth (and $$$ if you can find them).
I drilled around the perimeter with a 7/32" drill bit, using the flats of the bushing to a) shim the coupling to flat/horizontal and b) use the midpoint of every other flat on the bushing to set the points for drilling equidistant around the diameter. I then tapped those holes with a 1/4"-20 tap and used 3/4" set screws. Where I drilled, with respect to the face of the coupling, came from sort of eyeballing things. It's better here to be closer to the face than otherwise, or you won't be able to get the set screws into the groove of the dust cap. It ended up being close to the top of the ridge, and left some good meat between the set screw and the face. This drilling was easy, cast iron is not a big deal to machine, it seems.
After that, I added a 6 inch pipe and a flange for whacking and the tool was ready. Total of approx $24. Not as cheap as a muffler hanger or two but needs must
And now my dust caps are off. For sure it's the case that the set screws left marks but I think that's something that the Porsche tool does, as well, so I don't feel too bad. If the dust caps had ever been off before it was done with no damage.
On to the wheel bearings and general cleanup of the hubs!
That's a pretty cool idea.
Someday, someone will be going through your stuff, trying to figure out what to keep and what to throw away....without a clue what this is for.
Semi-retired, as of Feb 1, 2023.
The days of free technical advice are over.
Free consultations will no longer be available.
Will still be in the shop, isolated and exclusively working on project cars, developmental work and products, engines and transmissions.
Have fun with your 928's people!
That's a pretty cool idea.
Someday, someone will be going through your stuff, trying to figure out what to keep and what to throw away....without a clue what this is for.
Put it in a box, clearly labeled with "Spindle dust cap removal tool".
That's a pretty cool idea.
Someday, someone will be going through your stuff, trying to figure out what to keep and what to throw away....without a clue what this is for.
Yes, box it and label it. That someone going through your stuff in a few years and not knowing what it is could be you.
@sendarius I think that you could also do that without much issue. I didn't mention it, but while I was in the home store I looked for another bushing to reduce the size of the pipe even further, to get to something that was more amendable to the weight that I have on my normal slide hammer. I was not in luck, but you're absolutely right about being able to do something like that.
02-13-2021, 07:21 PM
Porsche 9165 Tool - Some clarifications on making your own
