Knackered old Porsche with loads of natural light - Boxster!

[Bright Halo]

eltax91 said:

braddo said:

Good to know, and I'm hoping it's rare, because I would be fking panicking if I had seen that at a track day and I would never have thought it might just be screenwash



ETA - reminds me of the first time a stone got caught in a brake disc/caliper. I was terrified - young guy, have taken my Elise into France for the first time, girlfriend was shouting, thought the car was broken. Mechanic friend suggested reversing a bit and seeing how it goes...

Edited by braddo on Thursday 6th June 21:35

There was, of course, an initial flurry of panic. But the liquid was obviously blue and upon closer inspection smelled very much like screen wash.

Didn’t take very long to witness it slowly leaking out of the nozzle tips

Nothing worse than a leaky tip.

[OvalOwl]

eltax91 said:

There was, of course, an initial flurry of panic. But the liquid was obviously blue and upon closer inspection smelled very much like screen wash.

Didn’t take very long to witness it slowly leaking out of the nozzle tips

Mild to serious panic for me when I came back to my 986 at Le Mans to find a damp patch under the driver's side radiator. No leak, just a local chien marking its territory!

[eltax91]

Bright Halo said:

Nothing worse than a leaky tip.

You should lookup the price of a replacement tip.

[poppopbangbang]

In the interests of continuous improvement I've managed to source a 4 Pin D shape male connector which is pin compatible with that moulded into the standard Coolant Temp Sensor. In short that means with a bit of 3D printing, soldering, potting and crimping we get a Coolant Temp Sensor which is plug and play with the standard 20V wiring harness but avoids the clash with the top of the engine bay when said 20V is in a Boxster

You can see the height difference here:



And plug compatible:



Pleased with that

[Mikeeb]

Does that mean less cutting of the engine cover?

[poppopbangbang]

Mikeeb said:

Does that mean less cutting of the engine cover?

No, it just means the engine fits with sufficient space around everything to allow for movement. You can get it in with the standard setup but it is on the loom from the CTS doing so.

This is the standard setup:



This elbow ends up under the metal work at the back of the engine bay. The clearance above the black connector to said metal work is too close.

This was my original bodge:



Which was fairly bulky and involved shrinking a boot down on it, I also couldn't get the mating half for the loom side connector so involved repinning the loom to a 4 way flat connector.

But the new one is properly potted to strain relieve the solder joints on the top of the CTS, is more compact so has even more clearance and has a mating half connector that plugs straight into a standard loom.

Basically it's all much nicer, it doesn't work any better or really change anything.... but it's nicer and sometimes nicer is all that matters

[poppopbangbang]

This is probably going to be a bit on the loud side, although the turbo does take a lot of energy out of the exhaust:





Big low loss CAT into a small 250mm silencer and then straight out the back!

I've designed it as a straight swap for the rear silencer that is on there at the moment so it's an easy swap back if it's too loud and obnoxious It'll definitely solve the current back pressure issue though!

[Bright Halo]

I thought you’d taken up the saxophone from the first picture!
That will certainly get rid of any restriction, interesting to know how loud it will be.

[poppopbangbang]

Bright Halo said:

I thought you’d taken up the saxophone from the first picture!

Let me play you the song of my people

[poppopbangbang]

Well all the exhaust bits / bends are on the way and should be here Thursday, I've got to decide what I'm doing with regards mounting it to the car next. I'm definitely going to retain the back of gearbox mount but picking up on that in a sensible way may require a bit of thinking as supporting an amount of adjustment is going to be the order of the day! I'm also a little concerned that the growth with temperature is going to make the tailpipe walk in the recess but we'll see how that works out....

PWR are on track with the chargecooler rad so that should be here in the next week or so, whilst I've got the bumper off to fit the the Chargecooler rad I'm going to get that painted as it's really letting the car down, it's been badly rattle can'd at least twice

As all the bits are within sight I've booked some more time on the dyno mid July. Really looking forward to running it again with the obvious bits resolved and seeing what it'll make

Finally it's off to CG post dyno for suspension so with that on there it's about done....... well nearly, I've got a few reliability mods planned including an electric water pump to keep the coolant circulating through the rads/engine/turbo when the engine is shut down and some further electronics integration between dash and ECU (and maybe a few extra sensors) so I can run downshift blip etc.

The big thing I'm pondering might be a bit polarising though.....





Cayman conversion - I expect it will be an utter arse as it's one piece GRP so almost certainly won't be the same side to side and it's designed to retain the soft top in a stowed position so will likely need some modification to support a Cayman style parcel shelf but I do really like the idea of a 986 Cayman! What do we reckon?

[wc98]

poppopbangbang said:

The big thing I'm pondering might be a bit polarising though.....





Cayman conversion - I expect it will be an utter arse as it's one piece GRP so almost certainly won't be the same side to side and it's designed to retain the soft top in a stowed position so will likely need some modification to support a Cayman style parcel shelf but I do really like the idea of a 986 Cayman! What do we reckon?

Oh yes, you have to do that. I think a lot of people would prefer that over the Boxt... sorry Booster. The exhaust will be fine, turbo's always damp a load of the noise out (says a man that was happy to run a straight through Quill exhaust on two GSXR 750's on euro trips, wouldn't dream of it now, far more considerate of others ears) i once had a back box fall off an Astra diesel and it made no discernible difference to the noise level though i appreciate this is a very different beast.

[Bright Halo]

It’s a no from me. One of the great attractions of the Boxster is the folding top and open driving.
Maybe next project could be a Cayman with a V8 conversion?

[mattdavies]

poppopbangbang said:

well nearly, I've got a few reliability mods planned including an electric water pump to keep the coolant circulating through the rads/engine/turbo when the engine is shut down and some further electronics integration between dash and ECU (and maybe a few extra sensors) so I can run downshift blip etc.

Really enjoy this thread.

On the above I am pretty sure that the seat Ibiza Cupra that first came with this enigne had this feature, I remeber a friends car making noise post shut down, therefore i am guessing an OEM style integration might be possible ( I dont know much about OEM ECU Electrickery )

[snobetter]

You just don't want the project to end. Neither do I, crack on!

[jeremyc]

poppopbangbang said:

Cayman conversion - I expect it will be an utter arse as it's one piece GRP so almost certainly won't be the same side to side and it's designed to retain the soft top in a stowed position so will likely need some modification to support a Cayman style parcel shelf but I do really like the idea of a 986 Cayman! What do we reckon?

How about trying something a little different for the Cayman: a normally aspriated, high revving screamer installation?

It won't have the absolute power of the turbocharged version, but might be a more engaging drive and also perhaps a lower cost and more easily packaged option.

[ATM]

poppopbangbang said:

The big thing I'm pondering might be a bit polarising though.....



I do really like the idea of a 986 Cayman! What do we reckon?

I've never driven a Cayman. I'm assuming it's very similar to a Boxster but with a fixed roof. If so why not just start with a Cayman?

The rear profile of the 986 with the standard hardtop is one of my favourite angles. Would there be any benefit to copying this exactly for the roof, remove the soft top and the clam shell and then make the bootlid bigger to incorporate the gap left by the clamsell. Maybe that would be simpler to fabricate but I'm no expert.

[trails]

poppopbangbang said:

Well all the exhaust bits / bends are on the way and should be here Thursday, I've got to decide what I'm doing with regards mounting it to the car next. I'm definitely going to retain the back of gearbox mount but picking up on that in a sensible way may require a bit of thinking as supporting an amount of adjustment is going to be the order of the day! I'm also a little concerned that the growth with temperature is going to make the tailpipe walk in the recess but we'll see how that works out....

PWR are on track with the chargecooler rad so that should be here in the next week or so, whilst I've got the bumper off to fit the the Chargecooler rad I'm going to get that painted as it's really letting the car down, it's been badly rattle can'd at least twice

As all the bits are within sight I've booked some more time on the dyno mid July. Really looking forward to running it again with the obvious bits resolved and seeing what it'll make

Finally it's off to CG post dyno for suspension so with that on there it's about done....... well nearly, I've got a few reliability mods planned including an electric water pump to keep the coolant circulating through the rads/engine/turbo when the engine is shut down and some further electronics integration between dash and ECU (and maybe a few extra sensors) so I can run downshift blip etc.

The big thing I'm pondering might be a bit polarising though.....

Cayman conversion - I expect it will be an utter arse as it's one piece GRP so almost certainly won't be the same side to side and it's designed to retain the soft top in a stowed position so will likely need some modification to support a Cayman style parcel shelf but I do really like the idea of a 986 Cayman! What do we reckon?

Looking forward to seeing the completed exhaust...and dyno is getting ever closer

FWIW I think you should sort a Cayman kit out as it feels like an easy win due to the amount of stuff you have learnt from the Booster. Just sounds like final packaging will be the main challenge....widens your potential market for sale of the kit, and probably stops people asking for a Cayman kit

Real challenge will be what you decide to call it

[ATM]

trails said:

Looking forward to seeing the completed exhaust...and dyno is getting ever closer

FWIW I think you should sort a Cayman kit out as it feels like an easy win due to the amount of stuff you have learnt from the Booster. Just sounds like final packaging will be the main challenge....widens your potential market for sale of the kit, and probably stops people asking for a Cayman kit

Real challenge will be what you decide to call it

Coostman

Caveman

Caymore

Coupester

[trails]

ATM said:

Coostman

Caveman

Caymore

Coupester

Boostman ?

[poppopbangbang]

mattdavies said:

Really enjoy this thread.

On the above I am pretty sure that the seat Ibiza Cupra that first came with this enigne had this feature, I remeber a friends car making noise post shut down, therefore i am guessing an OEM style integration might be possible ( I dont know much about OEM ECU Electrickery )

Yes very possible, that implementation was mainly to stop water boiling in the turbo whereas I am looking at a more significant pump that will still create some circulation but the principle is exactly the same!

ECU wise the Ignitron unit I use has a "stay awake" function based on coolant temp, battery voltage, elapsed time etc. so entirely possible to implement this ECU driven so it only runs when both the engine and bay temp are high (although one rather follows the other!).

The package works well and I've clocked up a decent amount of mileage so addressing the reliability boosters is a good option at this point as nothing significant will be changing in the integration etc. it'll just be getting used harder and harder