Porsche Boxster 986 - engine swap project

Porsche Boxster 986 - engine swap project

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Discussion

Escy

Original Poster:

3,906 posts

148 months

Thursday 9th June 2016
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I wasn't interested in the Boxster (or any Porsche really) either to be honest, I only bought one with this project in mind. Since i've started working on it i've been impressed by the quality of engineering. It's not hard to see where the money goes when you start taking them apart.

The air filter sits behind the rear arch liner.






eliot

11,361 posts

253 months

Thursday 9th June 2016
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Are you able to change the rods without rebalancing the engine?

Escy

Original Poster:

3,906 posts

148 months

Saturday 2nd July 2016
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It's been a while since I did an update. I fitted the rear bumper and decided the turbo was hanging a bit lower than it needed to be, it may have been vulnerable to speed bumps or high kerbs. I modified the mounting bracket to tuck the turbo up a bit higher. This meant re-doing the exhaust and the charge pipe. I re-wrapped the exhaust and manifolds as the stuff I used the 1st time was crap.



This is the turbo in it's new position and the space I have to design an exhaust system.




I wasn't sure what way to go with the exhaust. I wanted to make it 3.5". The options really are limited for silencers, bends and especially tail pipes. I randomly stumbled upon a 3.5" round to oval transition piece on a German website. It's looked like something that could pass as a tail pipe so I formulated a plan and bought a load of bits.



This might divide opinions, I'm having the 3.5" oval pipe alongside the screamer pipe for the external wastegate. It fills the bumper cut out nicely, I did consider the oval pipe by itself but it looked a little lost (Boxster has twin pipes as standard). I'm sure it won't be to everyone's taste, but I like it, it's all business. The system is a tight squeeze, it looked like there was loads of space but that space goes quickly with large diameter pipe work. I did think I wasn't going to be able to get an oval shaped silencer in, I nearly sent it back. It's tight for space pretty much everywhere and took me ages working out how best to design it but I'm really pleased with how it's turned out. I hope it sounds sweet and isn't too loud.







davepoth

29,395 posts

198 months

Sunday 3rd July 2016
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That looks awesome - only someone who properly knows their cars would give it a second thought.

superkarl

60 posts

136 months

Sunday 3rd July 2016
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You're deluded if you don't think that will be loud.

Epic build tho!

James 33

366 posts

103 months

Sunday 3rd July 2016
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The Turbo will muffle the sound quite a bit so don't think it will be too loud. Is the exhaust mig welded?

Escy

Original Poster:

3,906 posts

148 months

Sunday 3rd July 2016
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Yes, MIG welded.

Shadow R1

3,798 posts

175 months

Sunday 3rd July 2016
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Nothing wrong with that, great job. smile

abarber

1,686 posts

240 months

Sunday 3rd July 2016
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Looks wonderful! Can't wait to hear it when it's running / screaming!

djdest

6,542 posts

177 months

Sunday 3rd July 2016
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Oh that will be loud no question biggrin

mk2 24v

644 posts

163 months

Sunday 3rd July 2016
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That looks quite a nice route for the exhaust, may be a tad loud on full attack though laugh

And have you got a cat section for mot time? tongue out

PorkRind

3,053 posts

204 months

Monday 4th July 2016
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This is going to have the kind of tune the boxster should have begun with smile.

Krikkit

26,500 posts

180 months

Monday 4th July 2016
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Exhaust looks great, I get the feeling you might need a little more silencing though, that's going to be a touch indiscrete. biggrin

pstruck

3,518 posts

248 months

Monday 4th July 2016
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I've just found this thread and read it from start to finish. An excellent build and I'm intrigued to see/hear how it turns out.

Zombie

1,587 posts

194 months

Wednesday 6th July 2016
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Must be nearly ready to go by now by the looks of it... And it still has 7 months MOT. That was a stroke of genius OP. (Aside from the build itself, obviously.)

Escy

Original Poster:

3,906 posts

148 months

Wednesday 6th July 2016
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Thanks for the comments. Yes, the MOT was some good forward thinking, takes some pressure off when it comes to mapping and testing things.

I'm not far off now.

I need to finish off my charge cooler install, upgrade the fuel pump, install my data logging equipment and the big one, the elephant in the room - wiring!

Zombie

1,587 posts

194 months

Wednesday 6th July 2016
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Escy said:
Thanks for the comments. Yes, the MOT was some good forward thinking, takes some pressure off when it comes to mapping and testing things.

I'm not far off now.

I need to finish off my charge cooler install, upgrade the fuel pump, install my data logging equipment and the big one, the elephant in the room - wiring!
What are you using for data logging? I had an Innovate LM1 and wideband lambda running in the 156 I converted to GTA spec, great bit of kit.

Escy

Original Poster:

3,906 posts

148 months

Wednesday 6th July 2016
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I did look at that one but I've gone for a Zeitronix ZT-2. I like the fact it can display everything in one display. EGT, AFR, Boost, charge cooler water temp, IAT, etc. It means I don't need to have loads of gauges inside the car which it's the look i'm going for, I thought it might cheapen the interior with gauges all over the place.

I have to say i'm a little disappointed with the LCD display, I think it's been out for years and it looks it, it's the same height as a din slot which means I couldn't recess it in nicely into a spare din slot, the cable comes out the side so it can't be hidden and there is no provision for mounting it which means it's a velcro job. It's a shame they don't update it with something smaller than can easily be recessed, I could have made a slicker job of fitting it. I do like the fact it uses an RJ11 plug for the wiring (small broadband style plug), it means I can mount the main unit in the rear boot and make the wiring easy and just run a small cable through the car to the dash for the display.

The interior in this picture is a big bogging, a cat has been spending time inside it.



Edited by Escy on Wednesday 6th July 22:45

JordanTurbo

937 posts

140 months

Wednesday 6th July 2016
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Great progress.

Love the little and large tailpipes. It's the kind of thing a proper petrol head would notice when it's parked and give a little hint that something special is inside. cool

ikarl

3,730 posts

198 months

Wednesday 6th July 2016
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Absolutely fan-bloody-tastic

Exactly what it should've been from the start.

Is this the only build thread, or have you a more detailed one?