Ahsai

After checking with Jake and Tony, seems building a 3.8 is a no brainer so that's my current plan. Would love to attend those sessions but probably won't have time for now.

[QUOTE=cringely;12848211]

Ahsai

Jake, would be nice to know whether the engine we assembled runs well. I'm definitely interested in the online classes. Is the schedule out yet?

Flat6 Innovations

I'll let you know how it runs.

The class schedule is now written in stone for 2016. Here it is, as a snap peek, before its posted online. You guys are lucky, this last class restored my faith in offering classes. Until this past Monday we had no 2016 schedule, and I had pretty much planned on ditching the whole class idea. Kaley and I made this list yesterday, and it'll be on the site later this week with prices. (many prices will change):

Online Classes:

DF1(9A1) 101: February 8th & 10th
This online class familiarizes the attendee with the differences between the 9a1 and the engines that came before it. This class also provides an understanding of problem areas with engine internals and even unique service directives that have never before been associated with a Porsche automobile.

Most importantly, attendees that complete this class are pre- qualified for the Knowledge Gruppe LLC class “9A1 102 Engine Rebuild School,” which is a 4 day, hands on learning experience. This class covers disassembly and reassembly to the “long block” stage of completion. Attendees of all Knowledge Gruppe Engine Rebuild Schools will acquire the necessary knowledge to complete an engine assembly in their own garage, or shop.

Attendees of this class will benefit from the "first hand" content of this class and the photo documentation that Jake Raby has gathered since he began working with the engines upon their first application in 2009. Though these engines are the current and latest generation of Porsche flat 6 power plants, Jake has already experienced the pros and cons of the engine design and has developed several products and procedures to make the engine a more robust performer. With the 9A1 powered Porsches completing their warranty periods every day, its important for technicians and shop owners to understand the issues and challenges they will soon be presented with in their shops.

· 9A1 “101” Highlights
· Meet the 9A1
· Differences between M96 engines and 9A1 engines
· Engine configuration and layout illustrated
· Oil system function, to include PWM oil pump design and operation
· Unique 9A1 service and maintenance procedures
· Engine disassembly and reassembly
· What wears, what doesn't and why
· DFI integration and how it has impacted engine mechanicals, combustion chamber, piston and port designs.
· Performance modifications
*This class was specifically created to prepare attendees for the “Hands on 9a1 102” class, and is a prerequisite for attending this class


M96 Technician 101: February 22nd & 24th
This online only class is the pre-requisite for all individuals who wish to attend the M96/97 (hands-on) Engine Rebuild School. In this class Jake Raby and Tony Callas provide the basic information necessary to understand the shortcomings of Porsche’s most misunderstood engine. The team of Raby and Callas bring their unique experiences to the class, with Callas instructing the external points of the engine, and Raby focusing on the internals. In this class you’ll be able to attend from the comfort of your own home, while you receive 8 hours of instruction on the topics of:

· Meet the M96/97- Engine configuration layout and subsystems illustrated
· Basic M96/97 Engine Management, fuel trim, system resets and etc
· Cooling system design and function
· Oil System design and function explained
· Cracked Cylinder Heads, causes and effects
· All about scheduled service
· Engine Failure Illustrated-*The truth about on- track failures
· G force oil starvation, and other myths are busted!
· Meet the IMS Bearing, and understand its 4 Stages of failure, and how to both avoid, and preventatively address them!

Cayenne 101: March 7th & 9th
Most importantly, attendees that complete these classes are pre- qualified for the Knowledge Gruppe LLC class “M48 102 Engine Rebuild School,” which is a 4 day, hands on learning experience. This class covers disassembly and reassembly to the “long block” stage of completion. Attendees of all Knowledge Gruppe Engine Rebuild Schools will acquire the necessary knowledge to complete an engine assembly in their own garage, or shop.
Attendees of this online class will benefit from the "first hand" content of this class and the photo documentation that Jake Raby and Tony Callas have gathered since they began working with the engines. With the so many Porsche Sport Utility vehicles completing their warranty periods every day, its important for technicians and shop owners to understand the issues and challenges they will soon be presented with in their shops.

This class only covers content pertaining to the M48 V8 engine, it does not contain any information for the Cayenne V6 (VR6) engine.

· Cayenne M48 “101” Highlights
· Meet the 9M48
· Unique M48 design points
· Engine configuration and layout illustrated
· Oil system function, to include oil pump design and operation
· Unique M48 service and maintenance procedures
· Engine disassembly and reassembly
· What wears, what doesn't and why
· DFI integration and how it has impacted engine mechanicals, combustion chamber, piston and port designs.
· Performance modifications
*This class was specifically created to prepare attendees for the “Hands on M48 102” class, and is a prerequisite for attending this class


HI Performance 101: March 21st & 23rd
· This unique class spills the beans on the black art of creating an updated, high performance version of an M96/ 97 Porsche engine.

· The content of this class can be comprehended by those who have not attended M96 101 (online or when offered in the classroom) or M96 102, but attendance of these two classes is highly encouraged for those who wish to net the maximum benefit of the content that’s provided.

· Attendees will receive 8 hours of real instruction on the topics of:
-M96/ M97 Performance Basics
-High Performance Cylinder Heads (With Len Hoffman)
-Performance Lubrication
- Hi- Performance Shortblock Configuration Secrets
-Cylinder and Piston Secrets
-Understanding On- Track Oil System/ Engine Failures
-Intake To Tailpipe/ Sub- system Discussion
-Understanding Hi- Performance Camshafts
-Intermediate Shaft Mods for Hi- Performance
-Performance Coatings- Secrets and Myths
-Forced Induction and the M96/ M97
- 30 minutes of silver bullets!
-Dyno Tuning/ Understanding
-Performance ECU Tuning!


M96 Enthusiast 101: September 26th & 28th

*This class is for ENTHUSIASTS ONLY*

This online only class is the pre-requisite for all individuals who wish to attend the M96/97 (hands-on) Engine Rebuild School. In this class Jake Raby and Tony Callas provide the basic information necessary to understand the shortcomings of Porsche’s most misunderstood engine. The team of Raby and Callas bring their unique experiences to the class, with Callas instructing the external points of the engine, and Raby focusing on the internals. In this class you’ll be able to attend from the comfort of your own home, while you receive 8 hours of instruction on the topics of:
· Meet the M96/97- Engine configuration layout and subsystems illustrated
· Basic M96/97 Engine Management, fuel trim, system resets and etc
· Cooling system design and function
· Oil System design and function explained
· Cracked Cylinder Heads, causes and effects
· All about scheduled service
· Engine Failure Illustrated-*The truth about on- track failures
· G force oil starvation, and other myths are busted!
· Meet the IMS Bearing, and understand its 4 Stages of failure, and how to both avoid, and preventatively address them!


Hands On Classes:

M96 Technician 102: May 11th - 14th
On the first day of the class the group of attendees will disassemble M96/97 engines, and learn the basics of component layout as they go. The remaining three days of the class are dedicated to engine assembly of an updated stock M96/97 engine and labs. The labs during this class are a great value as 3 mock engines are used for both 3 and 5 chain camshaft timing, and wrist pin installation using different forms of factory, and Raby developed special tools.

The class is a fast paced learning experience with a real engine, real instructors and real problem solving. Each morning the class will view presentations about the written methods of that day’s planned assembly, and the in the afternoons everyone heads into the shop to assemble the engine. Though this class is “Rebuild School”, the attendees also learn a lot about disassembly and reassembly to support internal engine repair operations that are valuable for engines that don’t require a “rebuild” but have experienced a mechanical malfunction.
Put simply, when attendees of this class return home to their shops, they possess the confidence and knowledge to assemble an M96/97 engine in its entirety; and many do this. This class, like all Knowledge Gruppe Hands- on classes leaves no one behind, as the instructors will help those with lesser experience understand the processes. This class typically has 3 instructors, so there’s plenty of assistance standing by to help bring attendees up to speed without slowing the class down.

Attendees will receive 36-40+ hours of real instruction on the topics of:

· Special Tool selection & use.
· Machining, balancing, cleaning and preparing components for assembly.
· What parts to replace, and not replace during a rebuild
· Disassembling & reassembling an engine for repair purposes, rather than rebuild.
· Torque specifications and tightening sequences
· Cam timing on 3 and 5 chain engines (each attendee will set cam timing himself)
· Piston installation using special tools and Raby procedures (each attendee will install pistons)
· In depth information concerning cylinder heads, machining and deficiencies of certain models
· Complete engine disassembly and evaluation
· Engine reassembly to complete a “long block” assembly
· How to assemble a “leak free” engine using non- factory sealants and procedures
· Tons of “silver bullets” are given on the tricks of assembling an M96/97 engine



M96 Enthusiast 102: November 9th-12th
NOTE: THIS CLASS IS FOR ENTHUSIASTS ONLY.



On the first day of the class the group of attendees will disassemble M96/97 engines, and learn the basics of component layout as they go. The remaining three days of the class are dedicated to engine assembly of an updated stock M96/97 engine and labs. The labs during this class are a great value as 3 mock engines are used for both 3 and 5 chain camshaft timing, and wrist pin installation using different forms of factory, and Raby developed special tools.

The class is a fast paced learning experience with a real engine, real instructors and real problem solving. Each morning the class will view presentations about the written methods of that day’s planned assembly, and the in the afternoons everyone heads into the shop to assemble the engine. Though this class is “Rebuild School”, the attendees also learn a lot about disassembly and reassembly to support internal engine repair operations that are valuable for engines that don’t require a “rebuild” but have experienced a mechanical malfunction.
Put simply, when attendees of this class return home to their shops, they possess the confidence and knowledge to assemble an M96/97 engine in its entirety; and many do this. This class, like all Knowledge Gruppe Hands- on classes leaves no one behind, as the instructors will help those with lesser experience understand the processes. This class typically has 3 instructors, so there’s plenty of assistance standing by to help bring attendees up to speed without slowing the class down.

Attendees will receive 36-40+ hours of real instruction on the topics of:

· Special Tool selection & use.
· Machining, balancing, cleaning and preparing components for assembly.
· What parts to replace, and not replace during a rebuild
· Disassembling & reassembling an engine for repair purposes, rather than rebuild.
· Torque specifications and tightening sequences
· Cam timing on 3 and 5 chain engines (each attendee will set cam timing himself)
· Piston installation using special tools and Raby procedures (each attendee will install pistons)
· In depth information concerning cylinder heads, machining and deficiencies of certain models
· Complete engine disassembly and evaluation
· Engine reassembly to complete a “long block” assembly
· How to assemble a “leak free” engine using non- factory sealants and procedures
· Tons of “silver bullets” are given on the tricks of assembling an M96/97 engine


Technician Engine Management: Sept. 17th & 18th
Curriculum: We start the class by explaining all the Porsche scan tools and comparing their secret capabilities. Then we will cover Porsche's logic on the misfire and fuel trim systems, not just theory but how these systems actually work. We will cover the Bosch engine management systems in detail including the ME versions of 2.10, 5.2, 5.2.2, 7.2 and 7.8, comparing and explaining their differences. Cam timing affects engine management so we will be covering our virtual checking process via a DSO Scope.

Objective: Our goal has always been for you to be able to leave our class and immediately have the tools, logic and rationale you need to diagnose a Porsche (Bosch) engine management problem on the spot in short order. We hope to take the guesswork out and demystify the Bosch engine management systems.

To achieve this, the class utilizes several vehicles with induced issues, then the class will work in teams to solve these issues, utilizing various scan tools.

Attendees will receive 16-18+ hours of mixed classroom and hands on instruction on the topics of:

· Scan tools comparison and what they cover (Hammer, PST2, PIWIS-1 & PIWIS-2)
· *Scan tool Hands-On section
· Explanation and theory of all Porsche fuel injection systems.
· Camshaft deviation diagnosis utilizing a DSO scope.
· *Camshaft Deviation Hands-On section
· Fuel trim diagnosis technique simplified
· *Fuel trim Hands-On section
· Misfire fault evaluation and diagnosis techniques
· Diagnosis of all faults - Where to find the information you will need-GFF
· Testing the AOS utilizing a Manometer
· *AOS Testing Hands-On
· Variable camshaft timing and lift systems
· Explanation of all Evaporative Emissions Systems
· ORVR Refueling system explained
· ORVR Hands-On section
· Common-pattern failure items explained


* Denotes additional time spent on segment during this class



Enthusiast Engine Management: June 25th & 26th

*This class is for ENTHUSIASTS ONLY*
Curriculum: We start the class by explaining all the Porsche scan tools and comparing their secret capabilities. Then we will cover Porsche's logic on the misfire and fuel trim systems, not just theory but how these systems actually work. We will cover the Bosch engine management systems in detail including the ME versions of 2.10, 5.2, 5.2.2, 7.2 and 7.8, comparing and explaining their differences. Cam timing affects engine management so we will be covering our virtual checking process via a DSO Scope.

Objective: Our goal has always been for you to be able to leave our class and immediately have the tools, logic and rationale you need to diagnose a Porsche (Bosch) engine management problem on the spot in short order. We hope to take the guesswork out and demystify the Bosch engine management systems.

To achieve this, the class utilizes several vehicles with induced issues, then the class will work in teams to solve these issues, utilizing various scan tools.

Attendees will receive 16-18+ hours of mixed classroom and hands on instruction on the topics of:

· Scan tools comparison and what they cover (Hammer, PST2, PIWIS-1 & PIWIS-2)
· *Scan tool Hands-On section
· Explanation and theory of all Porsche fuel injection systems.
· Camshaft deviation diagnosis utilizing a DSO scope.
· *Camshaft Deviation Hands-On section
· Fuel trim diagnosis technique simplified
· *Fuel trim Hands-On section
· Misfire fault evaluation and diagnosis techniques
· Diagnosis of all faults - Where to find the information you will need-GFF
· Testing the AOS utilizing a Manometer
· *AOS Testing Hands-On
· Variable camshaft timing and lift systems
· Explanation of all Evaporative Emissions Systems
· ORVR Refueling system explained
· ORVR Hands-On section
· Common-pattern failure items explained


* Denotes additional time spent on segment during this class

501Max

Just in Time to work on the 2016 overhead education and travel budget. All CPA's need to be schooled in the fine art of the 996 motor is what I always say!

spruden

Awesome post - thanks for sharing. Looks like a lot of hard work - prepping for that kind of class takes care and serious investment...looks absolutely fantastic!

With this kind of knowledge, being shared in a purposeful and sustainable way, we the drivers of M96/97 cars are in good hands for the long term. Good stuff and thanks again for sharing. Pluses for the fire pit and beer drinking.

gnat

Awesome write up and info. I'd like to take the class just cause I'm curious, but I'll likely never be that far into an engine so I'd rather not take space away from someone that will get a more direct benefit.

Besides, I can't be bothered to find my drain plug

Jake, I don't understand this comment. Previously you've always said good things about the class experiences and the attendees. There haven't been many reviews of the classes, but all the ones I have seen have been just as glowing as posted here.

Is it just the stress/work of managing it all and it keeping you from actually working on engines or were there some problems?

alpine003

Has this class ever been offered before? This seems really interesting. Didn't really think about modifying an IMS Shaft for "HI" Performance before.

Is this all theory or will students be assembling an actual performance motor and tuning it as well(ecu tuning on a engine/chassis/roller dyno)?

Also curious to know if the 30 min of silver bullets will involve ISIS or Werewolves in any way?

Flat6 Innovations

Just one problem with two attendees who decided to be at odds with each other... I had to square them away, and it was a really childish situation that boiled down to an enthusiast being in a Pro level class. This is why I have created classes for each of the two followings. Leave it to people to ruin things!

When things start to be a pain in the ***, or they aren't fun, I stop doing them.... I don't have to do the classes, and it's just some extra cash to support my car/ gun habits...

That said, the classes really suck the life out of me... It takes two weeks to prep for a class, then the week of the class I generally get 2-3 hours of sleep as we have to spend the time after the class prepping tools and parts for the next day... That work can't be done ahead of time, since we build the engine live and real. It's not a dummy engine that won't ever run, and that's what makes the class what it is.

On top of that my personal build schedule is booked up, and I'd rather build engines as instruct classes. With development wide open on the GT4 engine, and soon to be on the new 9a2 turbo engines, I have a lot to get done in a short time. That's why this year we are only having 4 hands on classes; the rest are online.

As for the Performance Engine Class, we have been holding the classes live and in person. I moved the class online because the format of the class allows this, and it's 1/2 the price of doing it live.

30 minutes of silver bullets is a whole bunch of tricks.. We call those "silver bullets"

5CHN3LL

Wow, that went from "check out my bitchin' new classroom" to "this sucks, I'd rather be doing something else" in a hurry. Not that I blame you - I come close to throttling someone just about every day - and these are people I know and (mostly) like...

Flat6 Innovations

That situation happened in my very first class at the new facility... Since 2007 I had been doing classes at the main facility and NEVER had a single issue. Not even a smart comment.

The whole down stairs of the facility is my shop.. The upstairs is the classroom areas.. Most of the time I don't even go upstairs for the whole week.. Maybe to fire up the grill for a burger, but that's it.

5CHN3LL

Well, it certainly looked impressive from the photos you posted a while back.

I hope a couple of losers don't sour the whole thing for you, at least not for a while yet.

Cuda911

Yeah, as I was driving today I was thinking about that class, and how much work it would be.

I figured the 30 minutes of Silver Bullets was everyone around the fire pit slamming a six pack, each. Was hoping you had more class than to serve them Coors Light.

Flat6 Innovations

It's all good... This last class more than made up for it.. It was great.

But... Don't wait to attend, you never know when I am going to say to hell with it, and shut it down! I'll stick with it through 2016 for sure :-)

Valkuri

So: Online Technician 101 in February is the necessary prerequisite for the hands-on Rebuild Course planned for November? When can I sign up for these in tandem?
Separately: 30-06, or .300 WinMag for local boars? Inquiring minds want to know.

gnat

It never ceases to amaze me how people can't put differences aside for a couple days in situations like that.

Sucks you had to deal with that, but glad you stuck it through.