996TT Stage 4 Kit For Christmas

Last week we had a customer drive in from Iowa to leave his baby with us for a few weeks. Call it a Christmas upgrade. This Silver 996 Twin Turbo Cabriolet is getting our stage 4 kit, which will produce approximately 605hp at the motor. Without a doubt, the 996 is my favorite car to work on and drive, so it should be a good couple of days. Upgrades will include our larger turbos, a Fabspeed exhaust with 100 cell cats, custom headers, Evolution Motorsports V-flow air intake box, twin billet diverter valves, and a GIAC flash tune. I will also be putting in a clutch that is a little more stout to handle the horsepower, as well as a B&M short throw shifter. Last night i dropped the oil and put in the larger turbos. While replacing a turbo is not rocket science, everything must be extremely well protected during the install, as one single tiny piece of dirt in an exposed oil passage can ruin the turbo.

On the lift ready to go....


A new turbo ready for action....

Shot of one of the new headers.....

Next in line will be the exhaust and the clutch....stay tuned for a little magic.......ok, not really magic, but it is still pretty cool......

Update: December 06, 2005
Went after replacing the stock diverter valves with the billet units this morning. While they are hard to see, there are actually 2 diverter valves stuck back there. It is a very tight fit, and you wonder why spring hose clamps were invented, but once you get the stock clamps off, it isn't too bad of a job.

And the billet valves in place. We replace the stock valves because they have a rubber diaphragm in them that tends to fail after very short periods of time, especially under heavy boost. The billet valves have a billet plunger or diaphragm in them that will not fail. If your turbocharged car doesn't seem to make as much boost as it should, check your diverter valve first by sucking and blowing into the top nipple. If you can, then the diaphragm is shot.

After i got the DV's in, the Evo V-flow was installed to finish up the engine bay portion of the project.....

Update: December 7th:
Decided to go after the clutch this afternoon, since it is scheduled to arrive tomorrow via UPS, this way i could get the flywheel out and turned, and bolt everything back in place as soon as the clutch shows up. Porsche says you have to drop the motor to remove the tranny, but we disagree.

The tranny has left the car......

And there it is sitting on the craddle.....
Newly resurfaced flywheel waiting for a new clutch to show up.....

Update: Sunday Dec 11th:
Got the clutch in (left camera at the shop with the pictures), short shifter installed, fabspeed exhaust installed, and GIAC ECU flash tune done on Friday. Aaron was to deliver the car to the customer in Iowa on Friday night. Got it all together around 5:30, but the clutch pedal wouldn't go to the floor. Turns out the pin on the slave cylinder wasn't making contact with the clutch fork. Got that issue fixed, clutch bled, and the car warmed up and double checked on everything by about 10pm. He ended up leaving Saturday morning for Iowa, and by that afternoon the customer had the car. Another Stage 4 complete.