Knackered old Porsche with loads of natural light - Boxster!
Discussion
poppopbangbang said:
5harp3y said:
poppopbangbang said:
eltax91 said:
Ends tomorrow. £425 at present (plus fees) 
Seems almost rude not to have a spare at that price! 
5harp3y said:
poppopbangbang said:
eltax91 said:
Ends tomorrow. £425 at present (plus fees)
Seems almost rude not to have a spare at that price! poppopbangbang said:
I have another set of mounts on the way to play with
I got a set of these for my 986 but then decided not to fit them. I dont want to go on too much here if its not relevant so if you're interested then let me know.https://www.ebay.co.uk/itm/234268687380
Progress keeps progressing 
Motors in with most of the ancillaries now:
Just enough room for a 90 with a filter on the end which fortunately locates it just in front of the side duct so that will do for a phase 1 air inlet. Charge cooler also packages really nicely with plenty of room for a bay mounted rad fed by the side duct on that side.
The main clash around the back of the engine was the coolant temp sensor due to its vertical height coupled with the height of the loom side connector, easy fix for this was just to convert it to a flying loom. Ordinarily one would use a nice moulded boot for this but as I didn't have one to hand a bit of ahesive lined 3:1 was good enough
With this in place everything clears with plenty of room. A mating half for the 4 way square connector isn't available so I swapped this for a 4 way horizontal, as it's the same terminals in both this is just a case of depin one and stick the terminals into the other.
Finally test fitted the 987 engine cover:
As thought it will want a bubble in the back of it but only a little one to clear the back of the rocker cover so that's a simple job.
Next up is to work out the best route for the gear cables as there's a sodding great turbo in their way now
Motors in with most of the ancillaries now:
Just enough room for a 90 with a filter on the end which fortunately locates it just in front of the side duct so that will do for a phase 1 air inlet. Charge cooler also packages really nicely with plenty of room for a bay mounted rad fed by the side duct on that side.
The main clash around the back of the engine was the coolant temp sensor due to its vertical height coupled with the height of the loom side connector, easy fix for this was just to convert it to a flying loom. Ordinarily one would use a nice moulded boot for this but as I didn't have one to hand a bit of ahesive lined 3:1 was good enough
With this in place everything clears with plenty of room. A mating half for the 4 way square connector isn't available so I swapped this for a 4 way horizontal, as it's the same terminals in both this is just a case of depin one and stick the terminals into the other.
Finally test fitted the 987 engine cover:
As thought it will want a bubble in the back of it but only a little one to clear the back of the rocker cover so that's a simple job.
Next up is to work out the best route for the gear cables as there's a sodding great turbo in their way now
Another potential great base car if you can handle the dog cock red interior
https://www.ebay.co.uk/itm/325956487599?mkcid=16&a...
https://www.ebay.co.uk/itm/325956487599?mkcid=16&a...
mercedeslimos said:
I spy the cast aluminium pipe flange replacements, a real bugbear of older "modern" VAG stuff. Where did you pick those up? Mine arrived from AliExpress this week, even if the fit needs massaging they have to be better than the plastic that's breaking down nowadays.
These were no name from the internet ones, to be fair to them they aren't too bad at all but they do need some finishing - specifically all the casting flash taking off, especially from around the hose sealing surfaces! It's just not worth risking the plastic ones especially as on this install it'd be engine out to change it! Escy said:
Looking good, everything you do oozes quality. Do you have any concerns with a lack of airflow in the engine bay? The turbo is mounted quite high, you'll be able to do bacon and eggs off that engine cover!
It'll be fine (he says confidently ) The turbo will have a blanket on it and I'll make a heat shield for the manifold. The turbo is just above the side inlet so they'll be lots of flow across it and that side of the motor in general. If needed I can also take some air off the floor to provide some additional cooling but I don't think it will be needed. The engine cover area is pretty well insulated so it shouldn't cook the cabin but we'll see on that one as some will get through the bulkhead as there's some dead air space in the corners of the bay.I wanted to get the turbo up relatively high for a couple of reasons, one it meant I could use an OTS cast exhaust manifold which has benefits for the width of the overall package and also reliability as cast stuff is generally pretty tough vs fabricated steel or inconel and two it means there is some decent room underneath to run gear cables and coolant lines to the heater matrix.
Just a small wiring job to do now to make the VAG loom plug and play with the Boxster:
I've been through the original Porsche wiring diagrams to work out what's what and so far the wire colours and pin references match up so it can't be that far wrong I can't find a source for the standard connectors either so these were salvaged from the old loom with wire attached.
There are a couple of odities like the VAG loom has a seperate coil power relay on the loom so the main relay drive ends here rather than going off to the chassis and the Boxster has essentially two main relays one for coils and lambdas and one for injectors and actuators but hey that's what wire splices are for!
I'll put a few evenings into this during the week so it should be done shortly.
I've been through the original Porsche wiring diagrams to work out what's what and so far the wire colours and pin references match up so it can't be that far wrong
I can't find a source for the standard connectors either so these were salvaged from the old loom with wire attached. There are a couple of odities like the VAG loom has a seperate coil power relay on the loom so the main relay drive ends here rather than going off to the chassis and the Boxster has essentially two main relays one for coils and lambdas and one for injectors and actuators but hey that's what wire splices are for!
I'll put a few evenings into this during the week so it should be done shortly.
Edited by poppopbangbang on Monday 8th January 18:14
eltax91 said:
poppopbangbang said:
eltax91 said:
Perfect base car! Sub 100K miles, good colour, underside is all there and doesn't look to have been over anything too big. It'll be interesting to see what that goes for!https://www.copart.co.uk/lot/80500823/clean-title-...
Bright Halo said:
You really are getting a move on with this, great progress.
I think we of the PH world are all looking forward to this being up and running. Must admit as a 986 owner I am fascinated to see and hear how it drives with this conversation.
It's coming together quite quickly now, I found an hour or so this evening to get most of the loom done so I'm just waiting on a few VAG specific connectors from 3Way Comps now to finish it off. I think we of the PH world are all looking forward to this being up and running. Must admit as a 986 owner I am fascinated to see and hear how it drives with this conversation.
Once that's done it's just a basic plumbing up job of coolant, fuel, brake vacuum and EVAP. I've got a temp downpipe that I can do first fire up on so at that point it's time to see if it has oil pressure, starts and runs before the big job of actually putting it all back together properly with a throttle sensor, workable exhaust, all the necessary heat protection etc. begins. I've had a load of actual work work arrive but am still hopeful it won't be far off done sufficiently to go on the dyno end of Jan/Early Feb...... of course then I've got to draw it all up and document it and I really should do a basic FMEA / functional safety on it too! Oh and I've got to get it through emissions....
It should drive pretty much like a stock Boxster with a slightly different sound track.... until the boost arrives anyway. After all the gear box, clutch slave, mass and balance are all pretty much as standard so the controls and general chassis feel should be the same or near as makes no difference, that's the plan anyway
poppopbangbang said:
It should drive pretty much like a stock Boxster with a slightly different sound track.... until the boost arrives anyway. After all the gear box, clutch slave, mass and balance are all pretty much as standard so the controls and general chassis feel should be the same or near as makes no difference, that's the plan anyway
The only argument I've heard against v8 conversions in the 996 and 997 platform concerning weight distribution which sounded potentially valid was around the weight or centre of mass being higher up. Which can in turn lead the car to lean more or want to lean more causing body roll. Obviously a v8 is very different to what you have here but I'd be interested to know if there is any potential for a change of mass like this to be perceptible to the driver. I'd guess it isn't but obviously I'm just guessing. I’m not sure the cog is any higher and even if it is it can’t be by much. I presume the BAM engine even with turbo gubbins is a bit lighter than the flat six?
I think the above small differences only really matters when pushing to extremes. I’m sure it will feel slightly different but not in a negative way, just different. The power delivery will certainly be different but again just different not worse.
Anyway, intrigued to find out.
Great build.
I think the above small differences only really matters when pushing to extremes. I’m sure it will feel slightly different but not in a negative way, just different. The power delivery will certainly be different but again just different not worse.
Anyway, intrigued to find out.
Great build.
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