Lightweight pulley install
 

Difficulty level from 1 to 10 is 7

Price: $190

this mod added 8HP and 10LBS/FT to the wheels. very impressive

Remove the bolts holding up the luggage bar

http://i167.photobucket.com/albums/u...d/DSC04601.jpg

there is also an additional carpet pressure screw you have to pry out.

http://i167.photobucket.com/albums/u...d/DSC04602.jpg

http://i167.photobucket.com/albums/u...d/DSC04603.jpg

there are also little torx screws holding down the edge of the panels that I found easier to slide the carpet in and out when removing these.

http://i167.photobucket.com/albums/u...d/DSC04604.jpg

I used the pulley removal tool...

http://i167.photobucket.com/albums/u...d/DSC04607.jpg

before realizing that you can just use a screw as well...

http://i167.photobucket.com/albums/u...d/DSC04626.jpg

I have an audi, on the audi it also has this place to screw in a bolt to hold down the pulley. The Cayman :) has the same thing here. Just turn the pulley so that one of the holes are between 10-11 o'clock and thread the bolt in.

http://i167.photobucket.com/albums/u...d/DSC04609.jpg

This allows one person to remove the pulley with ease.

http://i167.photobucket.com/albums/u...d/DSC04608.jpg

once removed I use a cut off wheel to cut down the removal bolt sleeve...

http://i167.photobucket.com/albums/u...d/DSC04617.jpg

30seconds later... yes my engine is clean and yes I vacuumed the tiny micro aluminum dust particles. :)

http://i167.photobucket.com/albums/u...d/DSC04618.jpg

The new pulley is smaller but heavier.

http://i167.photobucket.com/albums/u...d/DSC04610.jpg

11.3oz for the stock one.

http://i167.photobucket.com/albums/u...d/DSC04611.jpg

13oz for the new one pulley (2.8oz heavier)

http://i167.photobucket.com/albums/u...d/DSC04612.jpg

The advantage is not in the weight but the smaller size. I matched the stock notch on the new pulley.

http://i167.photobucket.com/albums/u...d/DSC04613.jpg

http://i167.photobucket.com/albums/u...d/DSC04614.jpg

made a notch in it to match the stock one

http://i167.photobucket.com/albums/u...d/DSC04615.jpg

http://i167.photobucket.com/albums/u...d/DSC04616.jpg

put the pulley in place, it can only go on one way

http://i167.photobucket.com/albums/u...d/DSC04619.jpg

now use the installation tool provided

http://i167.photobucket.com/albums/u...d/DSC04623.jpg

tighten to 50nm plus a 1/4 turn

http://i167.photobucket.com/albums/u...d/DSC04625.jpg

use your torque socket wrench to measure the tightness :) and your done!

http://i167.photobucket.com/albums/u...d/DSC04621.jpg

actually put it back together and your done!
I dynoed the car... I will post it when I find it. This was a while back, 3 pulls the average was an increase of 5-8HP and 7-10LBS/TQ to the wheels. (Dynapack Dyno)