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987.2: Observations and a question

Got the Boxster in the garage today, jacked up and wheels off. God, are they ever HEAVY!

Need new rear tyres....they are evenly worn but are really close to the wear blocks, never run a car so close before, didn't realised they were so bad.

Took a long look at the Triangle Bolts. They are ready to be done, and soon.
On each side, 2 are easy to get to, cutting and drifting all do-able with a long punch bar, but the top one to the inside you can barely get a straight line of approach to knock the splined stud out. It looks a bitch.
Same on both side, mirror layout.

The two clamp rings are broken also on the twin outlet pipe Y piece, so it all needs doing.
Removing the silencer assembly off the car looks not too bad which would allow perfect access to the triangle of studs. I can't help thinking you have to remove the silencer to free the 3 studs.

So....the wife does not like the sound of any of this (bar the tyres) so has granted permission of pocket money advances to have the exhaust bolts done by a hardy indie like Zuffenhaus.

I've asked for a quote. I feel a bit wimpish about this tbh but getting old now!

At least this will have the car in top shape for the year and the road trip being planned.
As a final bonus, the car has been deliberately shunted from the drive to the garage, left to run a few mins , shut off etc 6 + times, and no start-up smoke so far.
 
911hillclimber said:
Got the Boxster in the garage today, jacked up and wheels off. God, are they ever HEAVY!

Need new rear tyres....they are evenly worn but are really close to the wear blocks, never run a car so close before, didn't realised they were so bad.

Took a long look at the Triangle Bolts. They are ready to be done, and soon.
On each side, 2 are easy to get to, cutting and drifting all do-able with a long punch bar, but the top one to the inside you can barely get a straight line of approach to knock the splined stud out. It looks a bitch.
Same on both side, mirror layout.

The two clamp rings are broken also on the twin outlet pipe Y piece, so it all needs doing.
Removing the silencer assembly off the car looks not too bad which would allow perfect access to the triangle of studs. I can't help thinking you have to remove the silencer to free the 3 studs.

So....the wife does not like the sound of any of this (bar the tyres) so has granted permission of pocket money advances to have the exhaust bolts done by a hardy indie like Zuffenhaus.

I've asked for a quote. I feel a bit wimpish about this tbh but getting old now!

At least this will have the car in top shape for the year and the road trip being planned.
As a final bonus, the car has been deliberately shunted from the drive to the garage, left to run a few mins , shut off etc 6 + times, and no start-up smoke so far.
Click to expand...


I had to replace the clamps also as they had split. Looks like a standard deal here with the exhaust deteriorating. I did indeed drift the splined section out once the exhaust is removed. Once the stud nuts are removed getting the exhaust off is easy. The thing with a rotary burr is you dont need to be in line, actually easier slightly off line.

Without the right tools getting it done is a good choice I would say. Im also getting a bit old for all this but stubborn determination kicks in !
 
Indeed, I'm not used to giving in on anything, but these look a pain and if it gets tough Mrs Hillclimber will tell me I should have gone to Zuffenhaus.
I can't leave the Boxster in the garage, so at the start of the day I need to be quite sure I can get the car back to the point of running at the end of the day!
Thus, taking the silencer assy off, doing all 6 studs and back together sounds difficult.
I was going to buy a grinder, 600W and up to 20K rpm 240v driven and a set of burrs, mostly acorn shaped.

I notice the studs are projection welded in place, 3 per stud 'head' to the sheet steel flange. I hope that is right, 987.2 was a different design to 981/986 systems.

If this is correct then the whole task could be simple, remove the welded stud heads using the grinder and the corroded fastener is completely free to come away with the silencer assy all in place.
So ground away, the fastener can be replaced with copper plated nuts and bolts, M8 in size with fresh gaskets.

I only found this picture late this afternoon, so will remove the one wheel again and see if access is free for all 3 on each side. If so, v tempted to man-up to the task.
My previous look today was assuming I would need to grind out the stud from the nut side where access is a pig to the upper inside location.
I think it is a different story if you only need to attack from the head side of the assembly.

Wedding anniversary tomorrow, so no garage time for a few days...

https://content.invisionc...f7192c55ac56231169.jpg
 
Ok your a little off piste now. Firstly the bolt is in fact a splined and flanged stud ,it looks like a wheel stud. It is not welded in but a press fit into a stainless steel sleeve welded to the header flange, for this reason cutting the head off wont help as you still need to drill or drift it out, its very tight. In that photo the sleeve has come off with the stud. Its not possible to cut off because the boss is shrouded by the flange return.

Also if you buy an electric die grinder then unless its very compact you will need one with a flex drive. Actually I have one but dont use it as it takes two people to operate plus the speed cant be varied like an air tool meaning things get out of control quite quickly !

If you only have a day its possible but must have all the parts and no issues. As you dont have the tools and also a tight deadline I would think get it done.


 
Ok, understand, the sliced sleeve is projection welded to the flange pressing, so it all looks gloomy!
wife has insisted Zuffenhaus do the bolts and the 3 clamps, and it is booked in for the 19 Feb.
need the tyres next week first, and with this lot done the errands are over on the Boxster!
the AOL is still in its poly bag, but no cold start smoke yet since the ECU upgrade.
 
Whilst happy to give most things a go, the 3 bolt exhaust I cheated and got my local indi (RSJ) to do, it cost £250 and they did it in a couple of hours. The secret is previous exeperince and the correct tools.
 
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