Two More 3.9L Projects Underway @ Shark Werks
02-22-2012, 08:25 PM
#1
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Two More 3.9L Projects Underway @ Shark Werks
It's been a while since we posted an update about our long term projects so I thought I'd start another thread. 
While I can't show everything we're working on, there's a new 3.9L 997 GT3 build that's unique. And on the lift she goes!
This car came in with approx 58,000 miles, mostly used as a track car and already equipped with a load of goodies: EVOMSit software, exhaust, full Ohlins 3-way coil-over setup, these HRE wheels, Guard LSD, roll cage, racing seats and all the gadgets for timing/video on track days. We are doing the 3.9L including a bottom end refresh and valve job, and the coolant leak fix.
Notice the HRE P40 wheels and wheel studs.
A short time later, James has reached a milestone in surgery:
With this kind of mileage, it's expected to have a little dirt and oil on the exterior.
It looks nice from this angle:
But a lot smaller from here:
A previous shop had performed a fix which was intended to seal the coolant pipes in place, by welding. Unfortunately the welds did not last or were not up to the job and therefore leaked over time. We now have to replace a couple coolant housings and fix these troublesome lines in place using a screw and loctite. More info on our solution is available here.
And a bit dirtier once the intake is removed:
The valve covers are removed:
More sludge removal and more parts coming off:
Now we're getting somewhere, with the pistons in plain sight.
The case prior to splitting:
And after, showing the crankshaft and oil pump.
And here we are giving the parts a bubble bath in our parts cleaner. This is quite a long process considering all the components to this engine. But it does ensure everything is clean and seals like new when reassembled.
While the parts soak, James turns his attention to this 2012 Turbo, which is receiving our exhaust upgrade:
Here's a video in case you were wondering how a new Turbo can sound compared to a GT3
Before we get back to work, a GT3RS comes in for some RSS suspension goodies and EVOMSit software, as well as our GT3 bypass exhaust.
Back to our big project, we can take a peak at the valves:
Since the car has higher mileage than we've seen and it's been driven very hard, it requires more attention on the internal bits for freshening up than a typical build. New connecting rod bearings and bolts are being used, and the heads are being worked on and I'll have some "after" pictures soon.
The results of the cleaning process:
Ready for new rod bearings.
Beginning reassembly...
The case is reassembled with new seals and the next step is pistons, which will have to wait for another post.
And as we're buttoning up this project, another is on its way. A white 3.9L 997 GT3 much like this one, and this time the car comes from Florida; its owner is also shooting for Ohlins and a handful of other upgrades...
While I can't show everything we're working on, there's a new 3.9L 997 GT3 build that's unique. And on the lift she goes!
This car came in with approx 58,000 miles, mostly used as a track car and already equipped with a load of goodies: EVOMSit software, exhaust, full Ohlins 3-way coil-over setup, these HRE wheels, Guard LSD, roll cage, racing seats and all the gadgets for timing/video on track days. We are doing the 3.9L including a bottom end refresh and valve job, and the coolant leak fix.
Notice the HRE P40 wheels and wheel studs.
A short time later, James has reached a milestone in surgery:
With this kind of mileage, it's expected to have a little dirt and oil on the exterior.
It looks nice from this angle:
But a lot smaller from here:
A previous shop had performed a fix which was intended to seal the coolant pipes in place, by welding. Unfortunately the welds did not last or were not up to the job and therefore leaked over time. We now have to replace a couple coolant housings and fix these troublesome lines in place using a screw and loctite. More info on our solution is available here.
And a bit dirtier once the intake is removed:
The valve covers are removed:
More sludge removal and more parts coming off:
Now we're getting somewhere, with the pistons in plain sight.
The case prior to splitting:
And after, showing the crankshaft and oil pump.
And here we are giving the parts a bubble bath in our parts cleaner. This is quite a long process considering all the components to this engine. But it does ensure everything is clean and seals like new when reassembled.
While the parts soak, James turns his attention to this 2012 Turbo, which is receiving our exhaust upgrade:
Here's a video in case you were wondering how a new Turbo can sound compared to a GT3
Before we get back to work, a GT3RS comes in for some RSS suspension goodies and EVOMSit software, as well as our GT3 bypass exhaust.
Back to our big project, we can take a peak at the valves:
Since the car has higher mileage than we've seen and it's been driven very hard, it requires more attention on the internal bits for freshening up than a typical build. New connecting rod bearings and bolts are being used, and the heads are being worked on and I'll have some "after" pictures soon.
The results of the cleaning process:
Ready for new rod bearings.
Beginning reassembly...
The case is reassembled with new seals and the next step is pistons, which will have to wait for another post.
And as we're buttoning up this project, another is on its way. A white 3.9L 997 GT3 much like this one, and this time the car comes from Florida; its owner is also shooting for Ohlins and a handful of other upgrades...
__________________
Dan Kennedy
SharkWerks: www.sharkwerks.com
Northern California's Porsche Performance, & authorized Evolution Motorsports, TechArt, HRE and Tubi, Cargraphic dealer and installation center
Phone: 510-651-0300
Email: dan@sharkwerks.com
SharkWerks' Latest Updates on Twitter
Dan Kennedy
SharkWerks: www.sharkwerks.com
Northern California's Porsche Performance, & authorized Evolution Motorsports, TechArt, HRE and Tubi, Cargraphic dealer and installation center
Phone: 510-651-0300
Email: dan@sharkwerks.com
SharkWerks' Latest Updates on Twitter
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02-22-2012, 11:48 PM
#8
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nice thread, like the documentation sharkwerks does. Fresh looking engine, keep the build pics coming. Dont just finish it and leave us all in suspense. This is interesting stuff, Not enough of this kinda threads on this forum. I love the build process and half the fun of cars is watching the work being carried out. I find it very enjoyable how things go together and how it works.
02-23-2012, 12:23 AM
#10
Rennlist Member
nice thread, like the documentation sharkwerks does. Fresh looking engine, keep the build pics coming. Dont just finish it and leave us all in suspense. This is interesting stuff, Not enough of this kinda threads on this forum. I love the build process and half the fun of cars is watching the work being carried out. I find it very enjoyable how things go together and how it works.
Wow. Thank you for sharing. The flying shark is awesome. Great branding!
02-23-2012, 10:00 AM
#13
The car under surgery belongs to my pal Cameron- as addicted to the track crack as anyone I know. Just an awesome guy and plenty fast 
Now he will be even harder to keep up with 
Great pictorial Dan! Keep up the good work.
Here is the hood badge of Cameron's car
Now he will be even harder to keep up with Great pictorial Dan! Keep up the good work.
Here is the hood badge of Cameron's car
02-23-2012, 11:13 AM
#15
Nordschleife Master
