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New magnesium crankcases for early Porsche 911!

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New magnesium crankcases for early Porsche 911!

The new edition affects vehicles of the F and G series with displacements of 2,0, 2,2, 2,4 and 2,7 liters. Among them is the legendary 911 Carrera RS 2.7, which celebrated its 50th birthday last year. The crankcases can now be ordered as original parts from any Porsche Classic Partner or Porsche Center worldwide. Previously, repairs had to either try to weld small cracks or used parts from old engines had to be used instead. The crankcase is the body part of the engine in which the crankshaft moves.

Magnesium crankcase

“With this new edition, we are once again closing an important gap. This allows us to build completely new engines for the vast majority of classic 911s,” says Ulrike Lutz, Head of Porsche Classic. "Demand from our customers for such engine components that are true to the original is very high." Porsche Classic is already working on further reproductions of crankcases from other 911 types.

New magnesium crankcases for early Porsche 911!

For two years now, aluminum crankcases have been available again for 911s with more displacement from the 90s. Blanks were taken from the warehouse for the production. The data set required for the machining was obtained using the reproduction of the Group C racing engine of the Porsche 962. Because the old engine drawings with production-relevant data were no longer completely decipherable. In addition, the experts from Porsche Classic viewed parts lists and technical information in the company archive and asked former and current colleagues about design details. The new version of the magnesium component now also benefits from this data set for the aluminum crankcase.

New magnesium crankcases for early Porsche 911!

With such a reproduction, Porsche Classic uses the latest and most mature modification status of the serial component at the time. All crankcases have a raw part number that documents this construction status. Furthermore, the reproductions are marked with the purchased part number.

Modern production under strict quality specifications

Based on the CAD data, a supplier casts the crankcase using the sand casting process. First, the corresponding molds are made in a plant and the cores are made of sand and a resinous binder. After casting, these cores are destroyed in order to remove the casting. The blanks are then machined on a five-axis CNC machine. More than 50 different cutting, drilling and milling tools are used. The material removal is low, for example on the milled surfaces it is only about three to four hundredths of a millimeter.

New magnesium crankcases for early Porsche 911!

The series production is accompanied by a complex quality control: the processed housings are individually measured using 3D measuring sensors. A comparison with the processing data is also carried out on a 3D coordinate measuring machine. The complete measurement includes over 1.300 control dimensions. For component approval according to the strict Porsche Classic quality specifications, a prototype engine also completed an extensive test bench run lasting several weeks. Porsche Classic used what was then the most powerful derivative, the 2,7-liter engine of the 911 Carrera RS 2.7, and equipped it with several sensors. The test program included endurance runs with precisely defined load conditions and different speeds. Numerous tests took place in between.

For example, the materials experts took oil samples and analyzed them for suspended particles and foreign matter. After the test runs, the prototype engine was dismantled down to the last screw by the Classic experts together with the specialists from Weissach. Every single part was assessed. Naturally, special attention was paid to the two halves of the crankcase. After complete disassembly, these were checked and examined again separately in the Porsche development center in Weissach. Similar test and measurement methods were used here, which also go through series components for the production release.

More than 80.000 original parts for classic cars can be ordered worldwide

In order for Porsche Classic to include the large number of classic Porsche vehicles as comprehensively as possible spare parts can supply, there is the original parts and accessories business area. More than 80.000 different spare parts and accessories can be ordered from any Porsche center worldwide. In addition to sales, Porsche Classic is also responsible for new editions of original parts that are already out of stock. Around 2013 spare parts have been reissued every year since 200. Technical literature is also available: more than 1.000 operating and operating instructions, repair manuals and the brochure "Types, dimensions, tolerances" (TyMaTo) can be ordered via Porsche Classic.

New magnesium crankcases for early Porsche 911!

Porsche Classic is continuously expanding its portfolio. Attractive lifestyle and accessory products increase the comfort and suitability of the vehicles for everyday use or enable the customer to add a personal touch to the vehicle. The latest infotainment systems from Porsche Classic are particularly popular here: PCCM and PCCM Plus. The fact that modern smartphones can be connected and that Apple CarPlay and Android Auto (PCCM Plus) can be integrated are the most important innovations in entertainment systems.

Furthermore, Porsche Classic has also opened up the "Performance Parts" segment. The aim here is to increase the performance and agility of the vehicles or to prepare them for use on the racetrack. This includes popular parts such as the performance steering wheels or the well-known Fuchsfelge®, which is now also available for newer vehicles such as the Porsche 911 (996 generation). An example of new and upcoming product developments are the performance chassis for the 911 generation 996 and the Porsche 959. These are developed in close cooperation with Manthey-Racing.

New magnesium crankcases for early Porsche 911!

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About Thomas Wachsmuth

Thomas Wachsmuth - He has been an integral part of tuningblog.eu since 2013. His passion for cars is so intense that he invests every available penny in them. While he dreams of a BMW E31 850CSI and a Hennessey 6x6 Ford F-150, he currently drives a rather inconspicuous BMW 540i (G31/LCI). His collection of books, magazines and brochures on the subject of car tuning has now reached such proportions that he himself has become a walking reference work for the tuning scene.  More about Thomas

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