Engine Rebuild School

 

 

 

 

 

One of the unique aspects about the Flat Six Innovations engine program is our desire to share knowledge and experience with the M96 engine with others....

Click the tabs below for information about our different periods of instruction.


M96 102

Effective 2/ 2015 our engine rebuild schools have changed! Our program is no longer affiliated with WTI, so we have been unchained to do things our way again. All training is handled through The Knowledge Gruppe LLC and are hosted at the Raby Engine Development Training Facility, located near Athens Georgia. 

 

We now  host more "M96 102 Engine Rebuild Schools" and other classes here at the Flat 6 Innovations advanced research and training facility per year. Jake Raby, Charles Navarro and Tony Callas tag team these classes from both a "101" (online only) and "102" (Hands on) level.  

Here are some details:

  • This is a hands on class with the attendees working together under the instruction of Jake Raby, Charles Navarro, And Tony Callas to "Rebuild" the M96 engine into "long block" state of completion.
  • We have added one complete extra day to the class from the previous curriculum to go over engine disassembly in detail, making a full four day, 40 hour experience.
  • Class size is 15 attendees, previous classes that were carried out more frequently were maximized at 10 attendees. We have added space and lab stations to facilitate more attendees, yet we have reduced class counts for the hands on classes to 15 attendees.
  • Our newly completed Advanced Research & Training Facility offers classroom spaces on two levels, with shop activities downstairs, and classroom environments upstairs. A total of three classrooms allow the attendees to learn in smaller groups and "change classes" between the classrooms learning a new topic with each change.
  • M96 102 Engine Rebuild School is for those who have attended in person, or have taken the 8 hour online M96 101  Class only. We require that all attendees first attend this basic class before being accepted fro the M96 102 Engine Rebuild School. 
  • We require all attendees to first attend M96 101 classes, then attend our Engine Rebuild school- NO EXCEPTIONS. This includes engine builders, technicians and those who are "well-versed", no matter their experience level. Our new online format makes this simple and easy, and much more cost effective.
  • In this class, held at Knowledge Gruppe Headquarters at a rural location in Georgia, the attendees pick up where the previous 8 hour Engine Mechanical Class with Jake Raby and Tony Callas leaves off.
  • This class has evolved since its inaugural class in 2008 to include at total of 4 days hands-on instruction with very little presentation/lecture included. This class gets the attendees out of their seats and into the shop to disassemble and re assemble M96 & M97 engines.
  • The dynamic duo of Raby and Callas are unleashed to instruct in their own unique ways; without formalities restricting the content or presentation. This makes for not only an informative class, but a truly entertaining experience!!
  • On the first day of the class the group attendees will disassemble M96/97 engines and learn the basic component layout as they go. The remaining three days are dedicated to engine assembly of an updated stock M96/97 engine and labs. The labs during this class are a great value as 3 mock engines are used for both 3 and 5 chain camshaft timing and wrist pin installation using different forms of factory and Raby developed tools.
  • The class is a fast pace learning experience with a real engine, real instructors, and real problem solving, in a real shop environment.
  • Each morning the class will view presentations about the written methods of that day's planned assembly. In the afternoons everyone heads into the ship to assemble the engine. Though this is a "Rebuild School", the attendees also learn a lot about disassembly and reassembly to support internal engine repair operations that are valuable for engines that don't require a "rebuild", but have experienced a mechanical malfunction.
  • Put simply, when attendees return to their shops they possess the confidence and knowledge to assemble a M96/97 engine in its entirety, and many do this. This class, like all Knowledge Gruppe Hands-On classes leaves no one behind, as the instructions will help those with lesser experience understand the processes. This class typically has 3 instructors, so there's plenty of assistance standing by to help bring attendees up to speed without slowing the class down.
  • Attendees will receive 36-40+ hours of real instruction of the topics of:
  • Special tool selection and use
  • Machining, balancing, cleaning, and preparing components for assembly
  • What parts to replace and not replace during the rebuild
  • Disassembling and reassembling an engine for repair purposes, rather than rebuild
  • Torque specifications and tightening sequences
  • Cam timing on 3 and 5 chain engines ( each attendee will set cam timing himself)
  • Piston Installation using special tools and Raby Procedures (each attendee will install pistons)
  • In depth information concerning cylinder heads, machining, and deficiencies of certain models
  • Complete engine disassembly and evaluation
  • Engine reassembly to complete a "long block" assembly 
  • How to assemble a "leak free" engine using non-factory sealants and procedures
  • Tons of "silver bullets" are given on the tricks of assembling an M96/97 engine

Our attendees range from novice level enthusiasts to 25 year veteran Porsche technicians, all sharing the common misunderstanding of the M96/ M97 engine when they arrived, but each left the Flat 6 Training facility with the required knowledge to assemble an M96 engine successfully the first time. In 2012 we even had technicians that are currently employed by dealerships travel to our facility to attend this class. In the words of one of them "Jake Raby taught me more about these engines in 3 days than I learned at the OEM school in 6 weeks!"

In 2013 we instructed classes that were attended by three of our four largest competitors in this industry. It says a lot when our competitor attends our period of instruction- They know the truth, though they'll never admit that they were here :-)

In 2014 and 2015 we have had many attendees from abroad travel from Singapore, Ireland and Australia for these classes.

 

General Class Information: 

Join us for a 4 day exploration into the "96th dimension" as we delve deep into the Porsche M96 engine. I'll share with you assembly procedures, tricks and secrets that we have learned during our manipulation of the M96/ M97 engine and the best part is the class is primarily hands on. This isn't limited to Rebuild skills, we also cover in-depth repairs that require invasive engine disassembly.

Who: Any Porsche Enthusiast or Professional Technician who has completed the M96 101 "Porsche M96 Engine Mechanical Class through WTI, or online

What: The Porsche M96 & M97 engine. We will focus on internal manipulations, assembly and the correct use of special tools required for engine assembly.

When:  SEVERAL CLASSES IN 2015 !!!

Our 102 Engine Rebuild Class will take place on October 7th-10th 

Our 102 Enthusiast Rebuild Class will take place on December 9th-12th 


Where: Flat 6 Innovations, Advanced research & Training Facility, near Athens Georgia

Cost: Standard enrollment is $1599.00 per person (no discounts for multiple enrollments) with a $400 upfront, non refundable deposit
Includes: Enrollment, class materials, shuttle to and from the hotel to the training facility facility, and catered Lunch. (complimentary shuttle service to/ from the Training Facility is limited to the first 10 attendees who request it)

400.00 non-refundable/ non- transferrable deposit due at the time of enrollment. The remaining balance of 1199.00 is due two weeks (14 days) prior to the class.

TRANSPORTATION: 
Note: Groome Transportation offers an airport Shuttle from Atlanta's Hartsfield- Jackson International Airport to select Hotels in the Athens area. We assist with logistics.

Class size is limited to 20 attendees to keep the content specific with plenty of first hand experience.

The deadline for enrollment is one month prior, or when the class fills to capacity (We reserve the right to close enrollment early should the class fill to capacity)

We reserve the right to postpone any class should the majority of it's attendees dis-enroll.

 

Enrollment in this class must be secured via a pre-paid 400.00 deposit. NO REFUNDS WILL BE GIVEN! ENROLLMENTS ARE NON-TRANSFERRABLE BETWEEN INDIVIDUALS OR CLASS PERIODS! This means YOU MUST ensure that you can attend this class PRIOR to enrollment. NO EXCEPTIONS. The remaining  balance of 1,100.00 is due within 14 days of the class period.

 Check, Credit Card and Paypal will be acceptable means of payment. 

 Please contact This email address is being protected from spambots. You need JavaScript enabled to view it.  regarding transportation and lodging for this seminar, we have completed a directive to assist with selection of travel and lodging.

NOTE: Classes are designed to cover the internals of the M96/ M97 exclusively, this is not a school about Emissions, DME or other sub-systems-- This is all about the "Heart" of the engine out to the cam covers. We offer many other classes about Engine Management and High Performance that will cover these other aspects of the M96/ M97 engine.

 

Remember: The Porsche M96 Engine "101" Mechanical Class is required to qualify for our M96 102 Engine Rebuild School. This is now an online- only class thats cheaper and easier to be a part of!

 

 

Testimonials

Enthusiasts and Professionals from as far away as California, Washington, Canada and Australia converge on the Flat 6 Innovations facility to gain the knowledge that will help each of them to successfully assemble the Porsche M96 engine.

 The attendees gain first hand knowledge from Jake Raby and Charles Navarro (of LN Engineering) through numerous presentations, lectures and first hand assembly labs that put special tools in the hands of future M96 engine assemblers and found them actually doing their part of assembling a 3.6 liter updated FSI test engine, or a stock Porsche M96 engine.

 

Here are a few testimonials from a recent attendees of the WTI Porsche M96 Engine Mechanical Class:

 

My experience in this class was very unique. Being a factory trained technician myself, I had a good grasp of the motor prior to even coming. The information, tips and experience shared with me were valuable on their own. The class made me even more comfortable and confident to work on, diagnose and build the M96/97 motors. Jake has a teaching style that is very understandable and is thorough on the explanations and answers to questions presented to him. Tony, of course, is always a riot to be around and I look forward to being in more of classes; his wealth of knowledge on Porsche overall is amazing. The catered food was delectable, and the cake from Jake's family was incredible! The atmosphere at the training facility is very home like, almost like going to a buddies house to tinker, without the beer. You can tell Jake has a lot of pride in his work with the collection of personal cars there. I've already recommended this class to two other technicians my first two days back from class. This class is a valuable asset to technicians not comfortable with the M96/97 motor, but is even MORE valuable to the owner/enthusiast that would attend. Having all of the fanatics in one room is an educational and memorable experience. Thank you Jake and Tony, you always make going to class an enjoyment!

 

Till next time,

 

Brandon Reeves

Schneider Autohaus

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While on a side step from the original topic since Jake posted a pic, Jake and Tony hold an incredible M96 class. With Jake's new facility, you wouldn't want to train anywhere else, it is above and beyond. The only issue you will have is finding ideas of ways to spend money on your own garage when you get back home   For the enthusiast, shop owner, or technician, it is worth every penny, even if you think you know it all.....you don't. I've been working on these cars professionally since about 04, and I learned a ton! Jake and Tony are both an incredible source of knowledge, and work very well together to keep the class informative and entertaining at the same time. It's hands on, jump in and get a motor built as a collective effort. I can't recommend it enough. From Jake's original picture, that is my ugly mug on the right.

Karl Wilen

Rennsport KC

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“My son, David, and I recently attended the PORSCHE M96 Engine course put on by WORLDPAC and taught by Tony Callas and Jake Raby. What an AWESOME course, there is so much information in this course, so many tips, tricks, techniques and “Silver Bullets” related to the PORSCHE Water Cooled Flat Six engines, that even if you do not perform engine repairs on these vehicles, it is well worth the price of attendance just so that you know the ins and outs of these engines. Taking this course gives you so much insight on these engines, it is just incredible.

 

To get the real world, hands-on experience of these two guys is priceless. Jake gives you the details that you need to help you make the decision if you even want to get involved in any internal repair of these engines. The procedures that Jake goes over and the tools required to perform the repairs are invaluable. The tips on dealing with the vehicle owner, your client, were very useful also. The facts that not only are you dealing with a broken vehicle, but a broken client, and how to break the news to the victim are very helpful and insightful.

 

The personal experiences that Tony and Jake bring to the table and share with the class were phenomenal. By putting together this course, and putting together this incredible information source, Tony and Jake have provided an invaluable service to the technicians and shop owners that service these very complicated vehicles, as well as an important service to the owners of these vehicles. This allows the vehicle owners to have another source to have their vehicles repaired properly outside of the dealership network. Tony and Jake have provided, in our opinion, an invaluable service to the PORSCHE community as whole.”

 

Omar Martin

David Camp-Martin

The Class of June 13, pictured below under the instruction of Jake Raby and Charles Navarro

 

Here are a few testimonials from recent attendees of "M96 102" Engine Rebuild School @ Flat 6 Innovations

 



 

The Engine Assembly class at Flat 6 Innovations was outstanding.  Jake Raby and Charles Navarro team up to deliver a powerhouse of knowledge and experience.  They combine mechanical ingenuity and technical savvy with an engineering approach that helps unlock the mysteries of the M96 engine family.  The classroom presentations are clear and concise, and are backed by a passion for understanding the Porsche breed and solving the inherent problems.  Students also get valuable hands-on training to confidently take on difficult techniques and procedures.  I thoroughly enjoyed the experience and left with a great deal of knowledge that is simply not available anywhere else.  It is rare to find experts who are willing to share their extensive and hard won knowledge with those of us who are new to the world of water coolers.  It would be a mistake to undertake an M96 rebuild without attending the class

Jeffrey Brubaker
M96 101/1.2011 Class


Dean,

I want to thank you and Jake, and Charles for the great class that Jason attended. He was very impressed with the presentation, and said it was well worth it. We look forward to developing a partnership in the future for engine repair. Please let me know how we might proceed in that area. I have been building Porsche engines for 35 years, and don’t intend to stop anytime soon.

I am also very involved in performance upgrades, and Jason mentioned you might be doing something like that in the future. I would like to be an attendee there, and hopefully could make a contribution.

Chris Powell
Chris's German Auto Service


I have just completed Jake Rabys M96 101 class and I got to attest that the three -day class has provided to me the most technically exhilarating experience in 30 years. Jake has masterfully taken the mystery out of this complex piece of hardware and presented it in a practical, easy to understand format. My learning curve on the Boxster has been exponential and I now have the necessary knowledge to properly maintain and upgrade my vehicle. It refreshing to listen and learn from someone who is a pioneer and expert in his field and Jake is nothing short of being prolific. I want to give kudos to Charles Navarro for providing his application expertise for this class.

Jim Orlando
February 2010 student M96-101 class


Hi Jake,

I just wanted to drop a note to let you know my first M96 complete rebuild was a success.  The only hiccup in the process was my reassembly of the oil pressure spring and piston in the vane assembly for the variocam.  I installed the plastic spring locater up-side down, which as you probably already know, limits the spring/piston travel and locks the vane assembly as if there were no oil pressure. The car now has over two thousand miles on the new engine and the owner is very happy.

As an aside, the day I got back to the shop after attending the inaugural M96 101 I was able to apply the knowledge gained through your instruction and not a week has gone by since that I haven't.  The confidence your class gave me to rebuild and even service an M96 engine has been invaluable. The rebuild process on the above mentioned engine went as smoothly as I could have ever imagined for the first time through.  I am pleased and proud to offer our customers a viable, long term solution to the problems a newer generation of Porsches are experiencing.

Thanks for hosting/teaching a great class and I look forward to doing business with you in the future.

Jason Williams
Chris's German Auto Service
Bellevue, WA


 

 

 

“My son, David, and I recently attended the PORSCHE M96 Engine course put on by WORLDPAC and taught by Tony Callas and Jake Raby. What an AWESOME course, there is so much information in this course, so many tips, tricks, techniques and “Silver Bullets” related to the PORSCHE Water Cooled Flat Six engines, that even if you do not perform engine repairs on these vehicles, it is well worth the price of attendance just so that you know the ins and outs of these engines. Taking this course gives you so much insight on these engines, it is just incredible.

 

To get the real world, hands-on experience of these two guys is priceless. Jake gives you the details that you need to help you make the decision if you even want to get involved in any internal repair of these engines. The procedures that Jake goes over and the tools required to perform the repairs are invaluable. The tips on dealing with the vehicle owner, your client, were very useful also. The facts that not only are you dealing with a broken vehicle, but a broken client, and how to break the news to the victim are very helpful and insightful.

 

The personal experiences that Tony and Jake bring to the table and share with the class were phenomenal. By putting together this course, and putting together this incredible information source, Tony and Jake have provided an invaluable service to the technicians and shop owners that service these very complicated vehicles, as well as an important service to the owners of these vehicles. This allows the vehicle owners to have another source to have their vehicles repaired properly outside of the dealership network. Tony and Jake have provided, in our opinion, an invaluable service to the PORSCHE community as whole.”

 

Omar Martin

David Camp-Martin