Intake madness. Teardown begins....
 

Please don't ask why. It's just madness.

I found an intake through another member. Early aluminum type.

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But - it didn't arrive without a hitch...

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So I'll figure that out prior to refinishing that piece. Total drag though. But that's life. If life gives you lemons...go drag racing?

Onward...teardown...this is going to be a boring endless set of pictures. And this project may take its time. So it won't be a daily thing, but it'll likely get somewhere. I'll apologize now if it ends up a pile of parts on my bench for years.

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and just prior...just for fun, i installed an aluminum WOT microswitch do-dad.

I had these made up a few years ago - so i have a huge inventory of these. Because everyone who hasn't replaced this little bugger - has a broken one. It just hasn't fallen off yet. Not to worry, cuz who cares if it falls off...you only lose a ton of hp since the resonance flap won't open....but no biggie. We didn't need that horse power anyway...lol

Anyway...here you go...

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And then- after fixing it with a set screw, I'm going to pop an E clip onto the shaft just to be sure it doesn't back itself off, though it shouldn't be necessary...but i like insurance

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You said don't ask why, but I'm gonna anyway. What is your goal with this teardown? Also I suspect I should order one of those WOT do-hickeys

+1 on do-hickeys - Please take my money!

I knew you were going to ask me why...cuz when you tell someone to not ask...

Pm me for the do-phramous...but if you are smart, you'll wait until i buy a box of e-clips in the correct size and I'll toss one in.

On another note. Those of you that look at the dbfd Facebook page will see the video of the little gagaramous that actuated the resonance flap...i was sucking on the vacuum tube (go ahead and make up a good one there) - butt just to see how much pressure it takes to actuate the flap and subsequently to see if that vacuum plunger was holding vacuum. Fascinating little guy.

Findings? I knew this resonance flap was sticky...but man it's REALLY sticky. Years of old oils caking in there and just humming everything up.

What's the plan?

Make it pretty.
Figure out how it all really works.
Test it against the later plastic throttle body, cuz i don't buy that the aluminum is "slower", as has been stated many times here. I think Porsche made the change simply because it was cheaper to make them out of plastic. The weight savings is minimal - and I'm not a weight weenie...so i don't worry about that. If i wanted a race car, I'd have bought one. And if i cared about weight in a street car, I'd have a caterham.

That said. I may go after some low hanging weighty fruit someday. Cuz 50 lbs is easy to find...but not today. Today is intake madness.

Oh- another interesting finding - the vacuum check valve is dead. Imagine- it didn't last 30 years. Who knew? That one is a 6 dollar part if you don't buy one from Porsche. Porsche is 25 dollars. Anyway. Easy enough to swap that out, but I'm not there yet.

Kevlar and dual wall adhesive shrink tubes coming soon.

More on that once i figure out what I'm doing.

Oh - and one more thing. I need to explore the resonance valve bushing. Everyone said the bushing/bearing or whatever it is, it's not replaceable or repairable. I don't buy that either. So i need to see it for myself.

I had a leak there many years back. The shop i was using at the time said "uh - has to be replaced" and a few thousand later, it was replaced. Did i need to spend that money. Was there another way? Enquiring minds want to know...

Anyway. Long story short. The engine bay needs help. I needed to renovate all those lines regardless. And i like to explore. But...my car is my only car. So i don't have the time to take out my intake and play with it. So having a second intake is the way. But since i have a second intake, i can do almost anything so long as it's within budget.

I had the best comment from a friend in Hong Kong last week...

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Not that i would ever start a company and call it by some incomprehensibly impossible name that doesn't roll off of anyone's tongue...singer at least was a sewing machine and has sonorous relevance....but a blank check for a corrected 964 would be a lot of fun. I've yet to drive a better car than a dbfd 964 (yes - them's fightin words- but our kids are always the coolest and best looking)...

And who has the best looking 964 on here? I do, of course!
As do you, and you, and you...

https://cimg1.ibsrv.net/gimg/rennlis...3e5593dea3.jpg

What is that you have wrapped around the shaft connected to the spring? Mine doesn't have it. (This is an old picture, the rust cleaned up!).

I think I'm missing what you mean? Which what wrapped around where??

Cleaning a few bits today. I have a lot more cleaning to do. This teardown is going to be lengthy. Super dirty and when you don't want to just replace everything...take your time and make determinations...

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The rubber on all of these is nice and relatively pliable- I'll replace the elbows cuz those don't use hose clamps. So newer and stickier is better...

Cruise control mech?

And back to cleaning and disassembly. I'm kind of amazed at how there are parts back there that had completely stopped functioning. Basically anything with a valve is all gummed up. Really makes me wonder what's in my car at the moment. When we did the top end build in 2011, the intake came off in large chunks and went back on in large chunks. So none of this was touched as far as i know.

Can't wait to disassemble the throttle body.
You all know i don't yet know if any of this is going to go back together....this is waaaaay more complicated than a suspension. And, btw, for far less real gain. Just sayin.

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Also- I'm amazed at how much oil is in these lines.

And take a look at this:

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That's the typical oil that that you find in the lower part of the throttle body when you take the stacks off. It was wet yesterday. Today it is dry and hard. So what gives?

Whatever it is- it's all through the system and causing the vacuum actuated parts to not function.

Did i mention that I'm also changing the charcoal canister when i do the install?

For now - I'm off to search for good quality and hopefully well designed or decent looking hose clamps. Hose clamp design, as you know, somehow has escaped the realm of those that care about looks. And so far all the decent looking ones have not much range. So i May just go for reasonable quality. And be done

These - no words really. I thought to maybe salvage them. Honestly not worth it. They need to go. So either new oem or aftermarket. I'm leaning toward oem for many reasons.

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Not sure yet. The lines are harder. And all of those seem to be salvageable. And the added hardness is a plus, so there is less inefficiency.

Haven't gotten to the slope yet. But everything that needs to be replaced is getting replaced.