Porsche Boxster 986 - engine swap project
Discussion
I fancy having a crack at daily driving it in the Spring so it'll be getting used in the wet. I'll get a K&N DryCharger cover for it. If I find that's not keeping it dry i'll make a shield for it to stop spray from coming up off the wheels. I'm not going to be wading through massive puddles in it.
Ozzie Osmond said:
Cooling - its surprising how much bigger the side air intakes are on 718 compared with 981. With turbos it's clearly vital to get some air moving about at the back of the car.
I like the 718 styling, but I think that engine is gonna need more than those new larger air intakes to cool things down!! 
Finished off the charge cooler install. I needed the rads off like this to properly bleed them, having clear pipes made the bleeding process much easier.
Finished it all up, quite a tight fit getting the rads and pipework in behind the bumper.
I had the bumper repainted as it was full of stone chips.
Finished it all up, quite a tight fit getting the rads and pipework in behind the bumper.
I had the bumper repainted as it was full of stone chips.
Barchettaman said:
Just awesome work.
The cooling system appears to be approaching Bugatti Veyron-esque levels of complexity. I love it.
Id be rather nervous with that setup, long length of pipes running back to front and back... The cooling system appears to be approaching Bugatti Veyron-esque levels of complexity. I love it.
Then again, its only the charge cooler, losing that would just mean hotter air, so less O2 in the cilinders, which a proper ECU should compensate for.
Thanks for the comments.
)
ooid said:
Meaning to ask about your CATS (Catalytic converters), can it pass the emissions with the current exhaust set-up? 
I've got no space for a cat with the exhaust as it is, the plan as it stands is to knock up a new temporary exhaust which will basically be a cat i've got kicking about in the garage bolted straight after the turbo and i'll lean up the fueling to pass the emissions, then swap it back to the 3.5" system (for track use )Vitorio said:
Id be rather nervous with that setup, long length of pipes running back to front and back...
Then again, its only the charge cooler, losing that would just mean hotter air, so less O2 in the cilinders, which a proper ECU should compensate for.
I'm confused, perhaps you don't understand the way it works? There is a heat exchanger in the boot, this has the hot compressed air from the turbocharger passing through it, it also has cold coolant passing through it (this coolant is a separate system from the engine coolant). With the charge cooler coolant, more capacity is a good thing as it'll take longer for the coolant to heat up (this also means longer to cool back down). This is why I added the extra tank in the boot, the fact the lines run front to back isn't an issue, especially as I've got a good pump, it does 24 litres per minute, that's 0.4 per second. My system takes around 15 litres of coolant so that's 37.5 seconds of full throttle before there will be a complete cycle of the coolant. No chance of full throttle for that amount of time on the road and I'm sure these new radiators will be good enough for the system to stay cool on track. Then again, its only the charge cooler, losing that would just mean hotter air, so less O2 in the cilinders, which a proper ECU should compensate for.
Thanks guys.
I took the car on it's maiden voyage tonight. It could have gone better, I made about 6 foot before I had a breakdown, I didn't even make it out of the garage! It looks like one of the power steering lines has rusted through, also an alloy fitting on one of the rubber p/s pipes has split so that'll need to be changed also.
I took the car on it's maiden voyage tonight. It could have gone better, I made about 6 foot before I had a breakdown, I didn't even make it out of the garage! It looks like one of the power steering lines has rusted through, also an alloy fitting on one of the rubber p/s pipes has split so that'll need to be changed also.
Escy said:
I'm confused, perhaps you don't understand the way it works? There is a heat exchanger in the boot, this has the hot compressed air from the turbocharger passing through it, it also has cold coolant passing through it (this coolant is a separate system from the engine coolant). With the charge cooler coolant, more capacity is a good thing as it'll take longer for the coolant to heat up (this also means longer to cool back down). This is why I added the extra tank in the boot, the fact the lines run front to back isn't an issue, especially as I've got a good pump, it does 24 litres per minute, that's 0.4 per second. My system takes around 15 litres of coolant so that's 37.5 seconds of full throttle before there will be a complete cycle of the coolant. No chance of full throttle for that amount of time on the road and I'm sure these new radiators will be good enough for the system to stay cool on track.
Yeah, i didnt know when writing that that the regular boxster has coolant running all the way back to front normally. Im not worried about the cooling capacity, i was just thinking that having coolant hoses running all the way through the car might be a tad less robust then having it closer to the engine (more pipe to get damaged/leak), but that shouldnt be an issue if its how porsche does it stock.Vitorio said:
i was just thinking that having coolant hoses running all the way through the car might be a tad less robust then having it closer to the engine (more pipe to get damaged/leak), but that shouldnt be an issue if its how porsche does it stock.
It is indeed in principle quite complex. Many boxsters, caymans and 911s(997.1) had coolant pipe/hose issues and needed proper fixings. The system has to be pretty tight and damage proof, if you get stuck in a traffic during summer the lag between radiators and engine does not help when you have a flat 6 working in full capacity.Gassing Station | Readers' Cars | Top of Page | What's New | My Stuff