For many years, Albert Motorsport has been overhauling Porsche Wasserboxer engines with a perfect repair method.

Labile Porsche Alu - Cylinders are completely removed from the engine block and replaced by new, solid and durable
Spheroidal graphite cylinder produced by centrifugal casting. This method creates a long engine life.

Emergency repairs or cheap compromises we completely reject,
because it does not help anyone in the long run.

Therefore, we do not perform the following repair methods:

  • Wir bauen keine Stahlbüchsen oder Stahlhülsen ein.
  • Wir bauen keine Alubüchsen oder Aluhülsen ein.
  • Wir führen keine Beschichtungen von Zylindern aus.


Why not you ask?

Several times a year we receive repair results from others
Motors - specialists to us in the operation. For renewed repair.

Here in the picture one such an example:


What happens to such repaired engines?!?

  1. Between aluminum and steel, we have different electrical voltage series that cause
    that cathodic currents form and corrosion on the surfaces between the cylinders
    forms.

  2. We have completely different coefficients of expansion between aluminum (23,1) and steel
    respectively Iron approx. (11.8), which inevitably causes the pressing surfaces to separate
    from each other (see picture) the seals - especially at the cylinder head area are leaking, and
    water penetrates into the space of the pressing surface. Now when the engine cools down,
    pulls the aluminum is stronger than the iron shell, and the cylinder can only burst, like easy
    to see in the picture. We have tons of such dilettantisch repaired engines already had in our
    company.

  3. The pressed-in sleeves are below the visible edge only under 1 mm thick. So about as thin as
    a simple body sheet! Completely different is the heat generation and the heat dissipation in
    this sleeve to the actual engine block, to the cylinders, the be lapped by the cooling water.
  4. The wafer-thin sleeves twist in the mold. The below in the crank mechanism attached holes
    lock the congruent holes to the cylinder, and a Dismantling the piston by pulling out the piston
    pin is now no longer possible.

    It must be cut off the connecting rods with the Trennjäger to the engine at all to disassemble
    again. Despite contrary views - yes, that's the way it is because we have such engines with
    us again and again!


Our solution:

A solid, separate, freestanding nodular graphite cylinder.

An engine block, in which we compare both variants for your info have
installed:


The advantages of our procedure:

Why spin centrifugal you will ask yourself - is not that too expensive?
Yes, centrifugal casting is a process for producing rotationally symmetric components.

During casting, liquid metal (melt) is filled into a casting mold rotating about its central axis.
Due to friction-induced shear forces, the melt is also set in rotation, and by the
Centrifugal force outside of the mold wall (the cylinder shape) pressed.

The rotational speed of the rotating mold is chosen so that high centrifugal forces act under
which the melt solidifies. Compared with the static casting process arises in this way
a structure with much fewer pores, and a higher degree of purity. This leads to clear
higher strength. The outer contour of the component is defined by the internal geometry of the mold.

In spheroidal graphite melting material, carbon is embedded, with a percentage above
produced by 2% emergency running properties and has only small dimensions. The exact same
Incidentally, material is also used for the known valve seat rings, which have been used for many decades
be installed in the aluminum cylinder heads of our Porsche.

I abbreviate the explanation, because that leads way too far ......

From this material now a complete thick, solid cylinder is made. He gets in on
Turned measure, and get below the area surrounded by the water a covenant, to rest in the
Porsche engine housings to be milled out.

Milled motor housing means that the dam .. eidenen series cylinder of the Porsche engines
now be removed to the connecting flange. The engine block gets a fit below,
and the cylinders are fixed there with an ultra-tough, highly heat-resistant epoxy adhesive.

The disadvantages:

  1. The costs are about 30% higher in production than the sleeves. (about 600, - Euro)
  2. The processing of the block can only be performed by specialized companies

Advantages: 

  1. The engine is now built from the ease of repair as a GT2 - GT3 engine

  2. Should a problem arise after years, the cylinders can be just like the GT3
    be replaced

  3. With the new cylinders, we have the opportunity to use a minimum of
    to carry out increase. From a 3.2 l. Boxster engine, is easily a 3.8
    to build liter. From a 3.4 liter or 3.6 liter 996 or 997 is easy to build a 3.8 liter.
    If desired, even a 4 liter engine.

  4. We now have a motor whose treads make a quantum leap better and more stable
    are, as the serial parts. Incidentally, it is the same material from which 20 years ago
    Mercedes taxi engines (200 D - 220 D - 240 D) were built, which partially up to a million
    km and longer. Truck diesel engines are built from the same material!

  5. We now also have a directly from the water completely flushed cylinder, without
    Thermal bridges and without the top of the head divided sealing surfaces.

  6. The freshly pressed and glued cylinder, with the complete engine block
    planned together. This results in a 100% straight surface on the cylinder head
    comes to bear.

  7. The cylinder used here, if it ever should be necessary, on 3 oversizes
    be turned up to stock with larger pistons, which we also newly manufacture
    to become.

  8. In the course of the cylinder conversion, the old pistons - read correctly - the old pistons on
    Shirt, (which is around the outside) machined below the piston ring zone and with a high strength
    open - pored nickel ceramic layer as a friction surface, which absorbs the oil molecules super well
    can, coated.

  9. It can be used as standard Porsche engine gaskets, which are now on the
    seal complete cylinder edge ......

This is how our solid graphite coated pistons look like:

Even so destroyed engines can still be repaired solid. If Seeing the break
below the cylinders, then you see the pedestal, which we turn to the seat
in the block freely, and on which the new one Cylinder sits.

... you can also see the break perfectly
The aluminum - silicon socket encased in aluminum.

There were made pictures under the scanning electron microscope with 1 million
magnification for us in which a comparison of aluminum cylinders with coating,
and our GGG40 Nodular graphite - centrifugal cast cylinders.


Coated aluminum cylinder

Our centrifugal graphite cylinder


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