EXHAUST HEAD BOLT REPAIR KIT FOR PORSCHE BOXSTER / 996 / 997
porsche spares made in britain by verboten-motorsport

EXHAUST HEAD BOLT REPAIR KIT FOR PORSCHE BOXSTER / 996 / 997

£300.00

EXHAUST HEAD BOLT REPAIR KIT FOR PORSCHE BOXSTER / 996 / 997

 

This Exhaust Head Bolt repair kit for Porsche Boxster / 996 / 997 is suitable for Porsche 996, 997 Gen 1, Boxster 986, Boxster 987 Gen 1, Cayman 987 Gen 1.

It is NOT  suitable for Porsche 996 GT3, 996 Turbo, 996 GT2 ,Porsche 997 GT3, 997 Turbo or Porsche 997 GT2.

This Exhaust Head Bolt repair kit for Porsche Boxster / 996 / 997  is a well designed and precision manufactured kit and enables you to remove and re-thread the Exhaust manifold studs without going through the pain of engine removal.

Having carried out a number of manifold removals we have created this kit to overcome the issues that are faced and makes a tricky job well within the ability of motor technicians and motivated DIY mechanics alike.

porsche-parts-exhaust-manifold-titanium -studs-manufactured-by-verboten-motorsport

Availability: 4 in stock

Exhaust Head Bolt repair kit for Porsche Boxster / 996 / 997

Boxster 986,987 .1 ,Cayman 987 .1 ,911,996,997 .1  Exhaust Manifold Stud Drill Jig Kit.  (Not suitable for GT3, Turbo or Cayman R)

This well designed Exhaust Head Bolt repair kit for Porsche Boxster / 996 / 997  kit enables you to remove and re-thread the Exhaust manifold studs without going through the pain of engine removal.

Exhaust Head Bolt repair kit for Porsche Boxster / 996 / 997

This Exhaust Head Bolt repair kit for Porsche Boxster / 996 / 997 just simplifies a tricky jobs and puts well within the capabilities of the motivated  DIY mechanic

The Porsche 996 is the fifth generation of the 911 model sports car manufactured by the German automaker Porsche from 1997 until 2006.[1] It was replaced by the 997 in 2004, but the high performance Turbo S, GT2 and GT3 variants remained in production until 2006. The 996 had little in common with its predecessor, with the first all new chassis platform since the original 911 and a new water-cooled engine. Technically, it was a major change, a complete breakthrough from the original car other than the overall layout.

The 996’s development was shared with the roadster-only Porsche Boxster (986) whose nameplate was making its debut as Porsche’s entry-level offering. The 986 was released shortly before the 996 for sales. Commonalities between the 996 and 986 included the front suspension, various interior components, and the engine, all of which were enlarged for the 996. However, the multi-link rear suspension was derived from the preceding 993. This was done mainly to save development costs as Porsche was facing financial troubles at that time. This move resulted in cost savings of approximately 30% in the development of the car.[2]

At its debut, the 996 featured the most significant change from the classic 911 series: a water-cooled engine replacing the previously air-cooled engine. Progressively stringent emissions and noise regulations, environmental concerns, a higher expectation for refinement and the need for a high-performance 4 valve per cylinder engine made the switch necessary. Other major changes include a completely new platform having a sleeker body with a more raked windshield, and a re-designed interior along with new “fried egg” shaped headlamps (so called due to the amber coloured turn signals) instead of previous “bug eye” headlamps.

This Exhaust Head Bolt repair kit for Porsche Boxster / 996 / 997 has been designed for use on your Porsche 911 996  Not Turbo, GT3 ,GT2

 

This Exhaust Head Bolt repair kit for Porsche Boxster / 996 / 997 just simplifies a tricky jobs and puts well within the capabilities of the motivated  DIY mechanic

This Exhaust Head Bolt repair kit for Porsche Boxster / 996 / 997 has been designed for use on your Porsche 911 996  Not Turbo, GT3 ,GT2

Manufactured by :

Verboten-motorsport-porsche-tiny-logo

porsche spares made in britain by verboten-motorsport
Porsche Boxster / 996

 

Weight2.4 kg
  • 1 x high precision CNC machined Aluminium location Jig.
  • 3 x high precision drill bushes manufactured in Hardened Hard wearing steel.
  •  1 x  high precision tap guide bush manufactured in steel.
  •  1 x standard length high quality European manufactured pilot drill.
  •  1 x long length high quality European manufactured pilot drill.
  •  1 x standard length high quality European manufactured core removal drill.
  •  1 x long length high quality European manufactured core removal drill.
  •  1 x UK manufactured high quality thread tap.
  •  1 x extension tap holder with ratchet feature.
  •  2 x  aluminium locator plugs complete with long and short grub screws.
  • Engineers pick for removal of bolt remains from threaded hole.
  • 2 x Allen Keys suitable for the bolts used in this kit
  • Strong plastic lidded case for convenient storage.

Usage Guide

This Porsche Exhaust head bolt repair kit for your Porsche Boxster / 996 / 997 kit comprises of a precision CNC machined drill jig.
It’s lightweight but robust to ensure your arms are as less stressed as possible when initially holding it in place.
We supply two Easy Locator threaded collars to either locate on the remains of broken off studs or from the threaded hole that remains after the occasional successful stud removal.
Ensure hole depths are measured prior to drilling and use of drill/tapping lubricant to cool and lubricate the drills.
The Exhaust Head Bolt repair kit for Porsche Boxster / 996 / 997  kit contains a hardened pilot hole drill bush that also locates over the remains of a exhaust stud if required.
Used in conjunction with the supplied pilot drill enables a pilot hole to be drilled in the stud remains. The drill bush is held in by the supplied drill bush locking screw.
Once the pilot hole is successfully drilled, the Pilot hole drill bush is replaced with the hardened Core Removal drill bush and again tightened down using the drill bush locking screw.
 After checking the correct depth the core of the exhaust stud is drilled out.
With this Exhaust Head Bolt repair kit for Porsche Boxster / 996 / 997  you are, with care, able to  reach the end holes in each exhaust bank to drill out the broken bolts. Frustratingly our competitors repair kit is not designed to accomplish this task. Having carried out this job under the car on many occasions we believe this is a invaluable for completing the job correctly and efficiently.
The remains of the stud can now be worked out using needle plyers and the supplied engineers pick.

Once the stud remains have been removed and then the thread hole is blown out with compressed air remove the Core removal Drill Bush from the Jig and insert the threading bush.
To identify this bush it is the one with the largest hole through it and big enough for the tap to fit through. Do however be careful as the thread tap and bush are both made of hardened material and the tap will be damaged by the bush if you use undue force ! This bush helps to ensure the thread tap is presented to the thread hole true and square. Carefully and slowly insert the tap into the stud hole using  thread tapping lubricant using the tap holder and socket extension on a ratchet to clear out the existing thread.
Once this is completed again use compressed air to blow out any remaining thread residue.Make sure you are wearing safety glasses or goggles as sods law dictates that the metal particles usually end up in you eye ! Once you are sure the thread  is clean you can move onto inserting your titanium studs.
We recommend using our specially formulated stud lock. This Stud lock has been formulated especially for air cooler cars and to not breakdown under the operating temperature. Only use the Stud Lock on the end of the stud that is being inserted in the cylinder head. Do not use it on the K-nut end.
Finally once all bolt remains have been removed go and have a beer or non alcoholic beverage of your choice to celebrate a job well done !
Other components we suggest you consider : Titanium Exhaust Manifold Studs : More Details Here High Performance Ceramic Anti-Seize Compound. : More Details Here

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