Stable Porsche Waterboxer engines from Albert Motorsport

?thumbnail=smallAt Albert Motorsport, defective Porsche cylinders are aluminum cylinders removed from the engine and replaced with chrome molybdane nodular graphite cylinders! New centrifugally cast cylinders ensure a long engine life. We reject emergency repairs and compromises.

  • We do not install steel cylinders or steel sleeves.
  • We do not install aluminum cylinders or aluminum sleeves.
  • We do not carry out coatings of cylinders.

Several times a year we receive repaired engines from "specialists" for renewed repair

our company, mostly from customers who bought Porsche technology cheaper on Ebay.

Below are some examples:

A wafer-thin steel cylinder after a mileage of 21,200 km.

(fracture of the aluminum cylinder jacket due to corrosion)


Bild 1. ( Copyright Albert Motorsport )

A Nikasil coating after only 5,500 km

( Detachment of the Nikasil due to poor adhesion on the aluminum )


Bild 2 ( Copyright Albert Motorsport )

What happens to these engines?!?

  1. Different electrical voltage series exist between aluminum and steel. These cause cathodic currents to form and corrosion to form on the contact surfaces.
  2. Different coefficients of expansion between aluminum (23.1) and steel (11.8) ensure that the unstable pressing surfaces separate from one another due to contact corrosion. ( see picture 1 )
  3. All the seals on the cylinder head are gradually leaking, cooling water gets between the cylinders and causes rapid corrosion. The cylinders warp, a gap develops and thus insufficient heat dissipation.
  4. When the engine cools down, aluminum shrinks more than the steel cylinder and can only burst in the long run. (Picture 1) Many customers then have to have it revised again and come to us.
  5. The pressed-in sleeves are less than 1 mm thick below the edge visible above.Only as thin as plain sheet metal! The generation of heat is completely different
    and the heat dissipation in these sleeves to the actual engine block, to the cylinders, which are flushed with the cooling water.
  6. The wafer-thin sleeves twist in the mold. The bores located below in the crank mechanism close the congruent bores to the cylinder, and is no longer possible to disassemble the pistons by pulling out the piston pins.

Our permanently durable solution:

Solid, free-standing ductile iron cylinders.


Porsche Motoren von Albert Motorsport - Bild 3 ( Copyright Albert Motorsport )

The advantages of the Albert Motorsport repair method for Porsche Wasserboxer engines:

Centrifugal casting ... isn't it all much too complicated?

Yes, centrifugal casting is a process for manufacturing rotationally symmetrical components.

During casting, liquid metal (melt) is poured into a mold that rotates around its central axis. The melt is also set in rotation by friction-related thrust forces and pressed against the outside of the mold wall (the cylindrical shape) by the centrifugal force.

The speed of the rotating mold is selected so that high centrifugal forces act, under which the melt solidifies. Compared to the static casting process, this creates a structure with significantly fewer pores and a higher degree of purity. This leads to significantly higher strength. The outer contour of the component is defined by the inner geometry of the mold.

Carbon is embedded in our nodular graphite melting material, which, with a percentage above 2%, realizes emergency running properties in engines and only shows small expansions.

I'll abbreviate the explanation...

A complete, thick, solid cylinder for Porsche is now made from this material. The new cylinder is turned to size on the inside and gets a wide collar below the zone washed by the water to rest on the Porsche engine housing to be milled out.

Milled engine housing means that the standard cylinders of the Porsche engines are removed up to the connecting flange. The engine block gets a fit and the cylinders are fixed with a highly heat-resistant special adhesive used in racing.

The contact surface for the cylinder heads is even wider. Here we are almost in close contact with only a few 1/10 millimeters between the sealing surfaces. The width of the sealing surface corresponds to almost twice the area of a standard Porsche cylinder.

Our new generation of cylinders, which we will be using from January 2020, has a hardness factor of 7 compared to the original Porsche cylinders. This creates lasting security in terms of service life.

The disadvantages of our method:

  1. The cost is about 30% higher to manufacture than the Nissan sleeves. (approx. 600 euros)
  2. The work involved in processing the block can only be carried out by specialist companies.
  3. The weight of the engine is marginally higher.

The advantages outweigh all the disadvantages:

  1. In terms of ease of repair, the engine is now built like a GT2 - GT3 Mezger engine
  2. If a problem should arise years later, the cylinders can be replaced again and again, just like with the GT3, but they can also be drilled out again.
  3. With the new cylinders there is the possibility of increasing displacement. From a 3.2 l. Boxster engine, a 3.8 liter. Build from a 3.4 liter or 3.6 liter 996 or a 3.7, 3.8 or 3.9 liter engine. If desired, a 4 liter or more is also possible.
  4. The running surfaces on the new engine are a quantum leap better and more stable than the series parts. A similar material from which Mercedes taxi engines (200 D - 220 D - 240 D) were built 20 years ago. These engines last up to one million km and beyond. Truck diesel engines are still made from the same material today!
  5. The new cylinders are now flushed directly by the cooling water. This creates an immediate release of heat to the cooling water, even during long sprints on the freeway.
  6. New cylinders are planned together with the engine block. There are 100% straight surfaces on which the overhauled cylinder head is mounted.
  7. Albert Motorsport cylinders can be turned on several times and, if necessary, rebuilt several times with larger pistons. That's what we call sustainability!
  8. When the cylinder is rebuilt, the old pistons - yes, you read that right - the old pistons are machined on the piston skirt (that's on the outside) below the piston ring zone and with an open-pored graphite layer as a friction surface grinding in on the cylinder, which Super good at absorbing molecules, durably coated.
  9. The standard Porsche engine gaskets can be used, which now seal the entire cylinder head and block perfectly.

This is what our revised pistons coated with solid graphite look like


Bild 4 ( Copyright Albert Motorsport )

At the breaking point, the thin aluminum-silicon bushing cast around can be seen.

We can even repair engines that have been damaged in this way. At the break, below the cylinders, you can see the base on which

in the future the new cylinder will sit after milling.


Bild 5 ( Copyright Albert Motorsport )

The following images were created under the scanning electron microscope with a magnification of 1 million.

An aluminum cylinder with subsequent Nikasil coating:


Bild 6 ( Copyright Albert Motorsport )

Our nodular chrome molybdane graphite cylinders, clearly recognizable by the blue graphite inclusions.


Bild 7 ( Copyright Albert Motorsport )

The comparison of an aluminum cylinder with a coating to a spheroidal graphite centrifugally cast cylinder makes it clear what makes the difference in the friction surface in the nano range. Even the oil in the engine cannot cover the properties that are required for an engine with an oil sump compared to nodular graphite cylinders with emergency running properties.

Albert Motorsport is a master mechanic company for Porsche,

we have been building Porsche engines since the mid-1970s and know how solid sports and racing engines are built. Many attempts have been made with all repair methods. The engines were tortured until it was obvious what the best option was. Over 1000 Wasserboxer engines were built at Albert Motorsport without any complaints. A 24-month guarantee and warranty gives you the security of buying quality!

I'm happy to answer any questions.

Best regards

Jürgen Albert

master mechanic