Porsche Boxster 986 - engine swap project
Discussion
chuntington101 said:
Escy said:
I don't think the hoses will need protecting but it's something I'll keep an eye on.
Yes, the engine radiators will be less efficient but it's no different to having a big intercooler in front of a water radiator and that's common practice.
No less effective than when you are running AC in sure! Lol Yes, the engine radiators will be less efficient but it's no different to having a big intercooler in front of a water radiator and that's common practice.
Only question is have is how are the radiator configured? Are you running them in serries or parallel? The size of the pipework looks pretty small so would think that parallel would be the best option.
Well it's been a *long* time since I looked at heat exchangers in university but the higher the temperature differential between the two the better the efficiency so I'd expect that parallel would be best.... however that's theoretical, differences in flow rates could scupper things.
purpleliability said:
Using water wetter is useful in charge coolers (I had one on my GT4) to help with cavitation. It's also worth protecting the charge cooler from any radiant heat underneath.
I've never added any additional cooling the the charge cooler itself but you could try some heatsinks on the top of the polished surface (plenty of space there) to increase the thermal efficiency of the box itself? Maybe some ducting to air cool the box too? Great project by the way, excellent work.
Thanks for the advice. I'll see how hot the charge cooler gets before I change anything. I think it's going to stay quite cool in the boot, there is the factory heat shield protecting the boot floor, it is mounted 15mm clear of the boot carpet so there is air circulation around it and it's directly above the gearbox rather than the exhaust. The tank does sit above the exhaust but that's likely to be warm anyway as it's just come from the charge cooler. I've never added any additional cooling the the charge cooler itself but you could try some heatsinks on the top of the polished surface (plenty of space there) to increase the thermal efficiency of the box itself? Maybe some ducting to air cool the box too? Great project by the way, excellent work.
chuntington101 said:
Only question is have is how are the radiator configured? Are you running them in serries or parallel? The size of the pipework looks pretty small so would think that parallel would be the best option.
The pipe work is 19mm. I'm running them parallel on the advice of Max Torque. I'm going to be data logging the charge cooler temperature so if I don't get the desired results i'll try them in series.These guys fitted heat sink fins to the core of their best intercooler : http://www.litchfieldimports.co.uk/Nissan-GTR/Race...
Air to air rather than water to air I admit but it might add a bit of stamina to your charge cooler core.
Air to air rather than water to air I admit but it might add a bit of stamina to your charge cooler core.
HughG said:
chuntington101 said:
Escy said:
I don't think the hoses will need protecting but it's something I'll keep an eye on.
Yes, the engine radiators will be less efficient but it's no different to having a big intercooler in front of a water radiator and that's common practice.
No less effective than when you are running AC in sure! Lol Yes, the engine radiators will be less efficient but it's no different to having a big intercooler in front of a water radiator and that's common practice.
Only question is have is how are the radiator configured? Are you running them in serries or parallel? The size of the pipework looks pretty small so would think that parallel would be the best option.
Escy said:
Yes, the engine radiators will be less efficient but it's no different to having a big intercooler in front of a water radiator and that's common practice.
super interesting project, been following for sometime. 
Mini question; What if you actually remove AC condensers and use original side radiators for your turbo cooling, and use the original main-front radiator of boxster S for the engine cooling? Making sure that also using waterless coolant (EVANs) -Not sure if its possible in your project? - so that even in extreme conditions you can avoid over-heating and etc..
ooid said:
Escy said:
Yes, the engine radiators will be less efficient but it's no different to having a big intercooler in front of a water radiator and that's common practice.
super interesting project, been following for sometime. Mini question; What if you actually remove AC condensers and use original side radiators for your turbo cooling, and use the original main-front radiator of boxster S for the engine cooling? Making sure that also using waterless coolant (EVANs) -Not sure if its possible in your project? - so that even in extreme conditions you can avoid over-heating and etc..
Little update. It's nearly ready for a test drive but i've got a couple of issues stopping the show, it's got a leak on the charge cooler system, i'm looking into using different radiators. I'm also having problems with the oil return on the turbo, it's leaking oil past the seals into the exhaust, ordered a few bits that will hopefully put it right.
I installed a catch can so that's the engine bay finished off. This is what I started with. That's the gear selector cables that run over the inlet manifold. Seems a bit of a lazy effort from Porsche. I've got them running under the inlet manifold on the V6.
This is how much space I have in front of the engine. I'm sure anyone with a 2.7t engine in an Audi will be jealous. I fancy my chances doing a cambelt change in-situ if required. Normally when doing an engine swap I find you end up with lots of straightforward maintenance jobs that become a nightmare. I don't think there is a single job that's going to be more difficult on this car than would be on a standard Boxster or Audi S4. You can see just by looking at the flat 6 how difficult access for various jobs, the V6 is a much easier engine to work on (provided it's not in an Audi!)
I added a heat shield to protect the CV boot from the exhaust.
I installed a catch can so that's the engine bay finished off. This is what I started with. That's the gear selector cables that run over the inlet manifold. Seems a bit of a lazy effort from Porsche. I've got them running under the inlet manifold on the V6.
This is how much space I have in front of the engine. I'm sure anyone with a 2.7t engine in an Audi will be jealous. I fancy my chances doing a cambelt change in-situ if required. Normally when doing an engine swap I find you end up with lots of straightforward maintenance jobs that become a nightmare. I don't think there is a single job that's going to be more difficult on this car than would be on a standard Boxster or Audi S4. You can see just by looking at the flat 6 how difficult access for various jobs, the V6 is a much easier engine to work on (provided it's not in an Audi!)
I added a heat shield to protect the CV boot from the exhaust.
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