Phoenix from the flames - Porsche Boxster with an Audi 2.7T

Phoenix from the flames - Porsche Boxster with an Audi 2.7T

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Escy

Original Poster:

3,960 posts

151 months

Friday 27th May 2022
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shalmaneser said:
Agreed that the mounting is critical but I reckon it could be done a bit cleverly and minimise intrusion into the frunk. I reckon the reduction in plumbing would definitely make it worth it.
My mate put one on his 987 with an Audi V8. They are quite big units so it's not that easy to hide and all my hiding places are already taken up. It would be nice to free up some space in the engine bay. If I run into power steering problems in the future I'll look into it a bit more. I'm thinking my latest pump failure was a bit of a one off.

Escy

Original Poster:

3,960 posts

151 months

Friday 27th May 2022
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Joey Deacon said:
I suspect that none of the results you get from companies that track your car are "perfect". They are probably good enough and because there is no point of reference nobody ever knows.

I suspect when your investigation has done is prove this fact, and if you are anything like me you want it to be absolutely perfect and spot on which is just not possible in reality due to variances in the equipment, floor etc.

I struggle to believe that some axle stands and a bit of string are more accurate than the machines you currently own.

"Perfect is the enemy of good"
I'm agree with you, small differences to adjustments make a big difference to the numbers. For example it's really hard to tighten my toe arms or track rods up without changing the values on the screen. If I'm measuring on a string kit it'll be to the nearest mm, definately not more accurate than the systems I've got but as you aren't seeing the values it's a case of ignorance is bliss.

If the car is driving straight and handles fine, that's all the matters. The issue is, I want to know it's right. If I could find someone to calibrate either of these systems I've got I'd be a lot more happy to use them. I can imagine it's expensive to the point of not being worth it. Both of these systems I've got were being used by garages for wheel alignments within the last few years so I'd assume they are in the ballpark.

Escy

Original Poster:

3,960 posts

151 months

Saturday 28th May 2022
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The systems I have are CCD rather than laser.

I put the cambelt on with all the covers left off so I could spot any leaks, I ran the engine for about an hour, as it warmed up, oil seeped from various places, cleaned it up and it didn't return. Other than the leak on the bank 1 cam cover which I knew was definately leaking before hand. It looks like what's been happening is the oil leaks on the cam cover seals, then either drips down onto various hoses and runs down them or runs across the back of the cam belt covers and ends up all over the place. This is pretty much what I thought was happening but when there is oil all over the place it's hard to be sure.

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My temporary engine mount while I ran it. You can see a drop of oil on the fitting for the oil cooler line, this was leaking and just needed pinching up.

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Leak from the cam cover seal I knew about.

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That's all I can do now, I've put it back together, just need to take it for a run and cry when it's covered in oil when I get back.

Escy

Original Poster:

3,960 posts

151 months

Saturday 28th May 2022
quotequote all
It looks like good stuff, seems less runny then the other stuff I've been using.

Edited by Escy on Tuesday 31st May 00:57

Escy

Original Poster:

3,960 posts

151 months

Tuesday 31st May 2022
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I've driven it for the first time. Come back and there is a small spot of oil on the sump, not clear where that has come from. Also looks like the cam cover is leaking on bank 1 yet again, oil dripping off and running down the coolant hose. Neither look terrible but it was only a short drive, it'll probably end up a huge mess after some decent use.

The first time I drove it I had a boost pipe pop off when it came onto boost, there were no leaks then. After fixing it and a few pulls, it's leaking. That explains why I could have it idle for an hour with no leaks and first time it sees boost it's leaking. It does point to crankcase pressure but I've spent a load of time developing the PCV system, if my figures are accurate it shouldn't be an issue. I'm just going to just have to live with the oil leaks. I think a 2.7t that doesn't leak oil only exists in fairy tales. Disappointing but what I thought would probably happen.

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Escy

Original Poster:

3,960 posts

151 months

Tuesday 31st May 2022
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I've done a compression test and a leak down test, there's no issues with the engine itself. Due to the design I can't ditch the seals as there is a large V that drops into a valley between the cam shaft caps. I could run silicone both sides of the seal. A previous owner tried that before and the oil pick up pipe was clogged up with silicone. Sure I can do a neater job.

Edited by Escy on Tuesday 31st May 14:40

Escy

Original Poster:

3,960 posts

151 months

Tuesday 31st May 2022
quotequote all
I might have judged that oil leak too soon. Been out for a longer drive in it today, the sump is a little bit wet still but it's not enough that it looks like it's going to be dripping off it. Not an immediate concern. The oil on the coolant pipes I showed a photo of in the last post has dried up, that could have just been residual oil from the previous leak, it's started running when everything has warmed up. Either way, the Boxster is out of the garage now and I won't get a chance to look at it again for a while.

I went to the local Porsche dealer in it, my boss was collecting his new Taycan. It's the rwd version with the performance battery. I really like it.

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We had a quick blast on the way home, it turns out my Boxster is comfortably faster, even with wheel spin and a traction control ignition cut (huge bang from the exhaust). That was without methanol also. I was chuffed about that, I had assumed because it's electric it'd be quicker. Hopefully my Boxster will stay together for a while now and I can get some decent usage out of it. I'm feeling a lot happier with it now than I was a week ago.

Played around a bit more with the wheel alignment stuff, have decided to get rid of it all. I've got it so it's driving alright doesn't pull but the steering wheel never seems to be straight. I'm going to pay for an alignment for now and I'll look into it all again when I have a bit more time. I still haven't turned the boost all the way up since it was on the dyno last year. I fancy going back on, just to see where it's at currently. My phantom knock issue I had which has stopped me using the knock control on the ECU has been traced to a software issue on the ECU, Baldur is working on a fix for it so once that's nailed down I'll probably go back on the dyno.

Escy

Original Poster:

3,960 posts

151 months

Tuesday 31st May 2022
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Yazza54 said:
The threebond I recommended is used to seal crankcases and all-sorts without paper gaskets, metal to metal. I have built a number of engines using it. I have never had a leak.

The only thing is it doesn't like being applied to an oily surface, but I don't think any sealant does...? If everything is clean and all surfaces that need to be sealed are coated in it I would expect it to work.
It does look good stuff, defiantly happy to give it a go. It's nice and thick, some of the stuff I've picked up at motor factors is a bit oily and running in comparison.

Escy

Original Poster:

3,960 posts

151 months

Sunday 26th June 2022
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Ever since fitting the big brakes I've had an issue with the ABS, if you are progressive on the brake pressure it seems to be alright but if you jump on them hard the ABS kicks in really early but doesn't actually do much to slow the car down, you get a hard brake pedal that feels like it's buzzing away but it's not slowing the car down. I'd have to come off the brakes and re-apply them. I'm not sure if it's technically correct or not but the internet seems to call this ice mode. When it happens it takes you by surprise, it's dangerous.

I've got a GT3 master cylinder, this is a common upgrade in Porsche circles I couldn't find anyone that's fitted the matching GT3 brake servo. I wanted to give this a try, using one off a spicy Porsche that had larger brakes, similar to what I have. I was looking for one off a 997 GT3, GT3RS, Turbo or GT2, as you can imagine parts off these models don't come up second hand often and when they do they are strong money, I think Porsche want around £700 for a new one.

With a bit of digging around I found the correct part, they are made by TRW for Porsche. It was £135 brand new in the box. I love a bargain and do my best to avoid Porsche tax. I figured even if it makes no difference it's worth rolling the dice on it for that price. The yellow dust cap had come off in the box and a few bits had worked their way loose and were rattling around but it all went back together fine so no big deal.

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This is the original one. The new one is a lot thicker, I did think it would be a nightmare to fit, I'd need to disconnect all the hydraulics but I managed to sneak it in with some fiddling.

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The plastic cover panel won't fit over it now so I cut it up a bit. Doesn't look good but it'll do for now. The one for a GT3, Turbo, etc is different, I don't know if it's a straight swap but I'll keep an eye out for one.

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Out for a test drive, the results are good, the meat of the brakes is more to the top of the pedal now, not better or worse than before in my opinion but a difference I noticed instantly. When doing an emergency stop the ABS kicks in and it actually stops the car like it should now so that's a result. Couple of pictures of the car out in the sun. It's filthy but looks clean in the photos.

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I also had another go with the wheel alignment equipment, put it back on and everything was bang on except the rear toe on the drivers side, I made that adjustment and it's driving spot on now and the steering wheel is straight. I'm happy with that. Not going to take it anywhere now.

A youtube video of this update but also with a couple of random driving bits chucked in, I'm biased but I think it sounds great.


Escy

Original Poster:

3,960 posts

151 months

Tuesday 28th June 2022
quotequote all
Yeah, it does sounds pretty mean with the exhaust valves open. I love it.

I've still had an oil leak but it wasn't that bad, both of the cam covers are sealed, it looks like it's from the sump again. I bought a complete engine gasket kit recently, one of the reasons was because it had a paper gasket for the sump. This is how it was originally from Audi and I've not been able to get another, I had to use pressed metal or silicone previously. I pulled the sump off and fitted the gasket.

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I've been for a drive and there isn't an oil leak in the same place as before. There still was some oil on the sump but I'm pretty sure it's run off where I made a mess filling it back up with oil. I'm going to whisper it but I think the oil leaks could be solved.

I've ticked off the ABS issue, wheel alignment and oil leaks (hopefully). I feel like it's nearly done now, there's just two things left to address I think. One is the problem with knock control on the ECU. That's a software issue their end, it's being worked out so I just need to wait for an update to be released. Once that's fixed I think I'll get it back on the dyno to see where it is. We were getting inconsistency's last time, two separate runs at the same boost and timing, one would be fine, one would have some knock. I had the VVT solenoids working the wrong direction and the cambelt ended up slack which explains that, I've also changed the air intake since so it'll be good to see the difference although I'm not really expecting much difference to peak power.

The second thing I need to do is get the aircon working, it's been gassed up but the climate control isn't sending the request to the compressor, I'm pretty sure there's a missing a message on the CANbus, as soon as the engine starts the climate control module goes into an error state (on PIWIS).

I've also got some bodywork stuff I want to do also but I've been waiting on parts from carwebshop / madmotors since February, I think I've been scammed.

Escy

Original Poster:

3,960 posts

151 months

Tuesday 28th June 2022
quotequote all
JonChalk said:
Their Google reviews would tend to confirm that view, sadly.
Yeah, looks that way. Wish I'd looked at reviews before buying something from them.

Escy

Original Poster:

3,960 posts

151 months

Tuesday 28th June 2022
quotequote all
Peanut Gallery said:
I agree, that sounds mental - in a good way!

Enjoy it! - and save up for more tyres, its a worthy expense!

Complete armchair person here, but how about a large (say 15mm ish) vent pipe straight from the block to a low pressure section of the exhaust, near the rear. No one-way valves, nothing to restrict the flow. If some exhaust gases go back the way into the block would it be an issue? - I'm guessing that the block vent system cannot cope when you give it the beans, increasing pressure and blowing seals.
I'm running Yokohama AD08R, I find them really good but think I'll get through them quite quickly.

I'd expect the oil would get carbon deposits from the exhaust and be dirty quite quickly if there was an unrestricted breather pipe. Also the ignition cut must cause massive pressure spikes which would likely be the cause of leaks. I think the current breather setup is working adequately, time will tell though.

Escy

Original Poster:

3,960 posts

151 months

Wednesday 29th June 2022
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roadie said:
Incredible. What a project.
Thanks!

The Wookie said:
Not sure if it's helpful info or not but if it's anything like the BMW system I've been reverse engineering for my Landy then the climate control unit sends the demand to the DME (in the case of the BMW it's just an on/off voltage but could just as easily be a CANBUS communication) and then depending on engine speed/load/temps/etc etc the DME decides if it wants to engage the compressor/fans/etc and then activates the relay for the compressor
Mine is similar the climate control sends a CANbus message the the ecu, the ecu is responsible for activating the relay for the compressor and sending a return CANbus message to the climate control module. This is all set-up, the issue is, the climate control goes into an error state as soon as the engine is started. It's not seeing something it wants on the CANbus network. I'd guess it's related to the engine running message. The Porsche diagnostics aren't much use, I just get a general error code rather than anything specific and because it's in an error state I can't see what data is missing. I need to spend a few hours going through all the CANbus information I have and trying to work out what's wrong missing. My understanding of the CANbus side of it all is basic at best so I keep putting it off.

Escy

Original Poster:

3,960 posts

151 months

Wednesday 6th July 2022
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bungz said:
well done, fingers crossed for the new gasget.

have always found tin compression ones very hit and miss in my limited experience.
Yeah, I'm not a fan of them. I prefer paper gaskets and all the OEM Audi ones are paper as far as I can remember.


therealsamdailly said:
Fair play that looks/sounds like an absolute weapon on the road!
It does go really well and I love all the turbo noises. I'm really happy with it.

Escy

Original Poster:

3,960 posts

151 months

Saturday 16th July 2022
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Since I reversed into the kerb by my house and damaged the old bumper I was looking for a replacement. I spotted someone selling a SportDesign rear bumper on ebay, wrongly listed as being for a Cayman when it's Boxster specific. The SportDesign package is the bodykit offered by Porsche, they were about 5k to buy (no longer available), it consists of a different rear bumper, some corner pieces for the front bumper and a different rear spoiler. The corner splitter bits for the front bumper are available from the aftermarket (I ordered from a scam website 6 months ago, but have now re-ordered from Design911 now), the rear spoiler took some digging around but I managed to find a company in Germany that make it out of carbon fibre. That makes only the rear bumper the unicorn part of the kit, nobody makes them in the aftermarket. I bought all the parts at the start of the year. Porsche describe the bodykit as inspired by the Carrera GT. I can't see it myself which is good as I don't want anyone to mistake my car for one of them, they'd assume I have 100ft/lb less torque than I do wink

The plan was to wait until all the parts turn up and then get the front and rear bumpers painted before the summer but I've been waiting so long for the front bumper bits that it's messed that all up. I'm sick of seeing the new bumper sitting in the garden so as it was silver I decided I'd try polish the marks out best I could and fit it. The seller who shipped it to me didn't protect it, just chucked it in the back of a fan with a label taped to it so it picked up plenty of scratches. It's come up reasonably well, it looks fine on the car. This was as it came before I polished it.

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The carbon fibre spoiler, nicely made and was a fairly reasonable price (until my Brexit bonus added £150 onto it)

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You'd think it's all straight forward to fit but I managed to balls it up, had a bolt cross thread on the ram for the spoiler, there is a hex bit in the end to hold it but it eventually rounded so I put an impact gun on it. I didn't know at the time but it cracked the housing for the ram and it became disconnected from it's cable. I put the spoiler down and this happened.

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I heard cracking noises coming from the spoiler before I noticed what was happening. Luckily this is the only damage I can see, the mark at the side of the mounting. The factory spoilers have plastic covers to hide the window for the bolt, I don't think they are available from Porsche so I just used some silicone sealant to hold some rubber hose in place as a temporary thing. It looks like the ideal job for a 3d printer if I ever get one.

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Stripped the spoiler mechanism apart, there's quite a bit going on here.

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I repaired this and now it all works fine.

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This is how it looks, spoiler down.

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The spoiler up.

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One oversight is the bumper was missing the surround over the exhaust, I expected the one off my old bumper to fit but it doesn't. I don't think I get one from Porsche (if anyone knows the part number, let me know). It's not that noticeable when on the car, I might need to just get some dodgy stick on trim to cover it. You can also see a crack on the bumper under the number plate, that'll be sorted when it's painted.

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The headlights were looking a bit cloudy I took them out to polish them.

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In the next instalment of me being cack handed, the polisher caught the headlight and knocked it onto the floor. It landed on a brake disc and ut it cracked the edge of the light, which you can see by the indicator. Should have polished them on the car. In terms of the polishing, they came up alright but I had a spray on coating to protect them from UV damage and that seemed to make them a little bit cloudy again, not that impressed with it.

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I was looking about for a replacement headlight and found some carbon fibre trim bits that would stick on and cover it. Thought that was worth a go as it ties in with the new spoiler.

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Fitted. Porsche blacked out the edge of the headlights from the factory on the 997 Sport Classic and it's a thing people often copy (usually with vinyl). I think I like them but it will take some getting used to. None functional stick on stuff does have a whiff of 2000's Max Power.

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Escy

Original Poster:

3,960 posts

151 months

Sunday 17th July 2022
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Definitely not wanting to do that. I'm not sure how I feel about the centre lock style wheel cap. As a design, I like it, I think the red adds something but I don't like things pretending to be something they aren't. Those wheels on a Golf, everyone would instantly know its just the design, nobody would think they are real but as Porsche are associated with centre lock wheels, there's been a few occasions where people have pointed out the centre locks thinking it's the real deal and been disappointed on closer inspection. It feels a bit embarrassing when that happens.

They look decent without the centre lock cover. I might try that look at some point.

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Escy

Original Poster:

3,960 posts

151 months

Monday 18th July 2022
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Pupbelly said:
Every time I log in to this thread I'm blown away by the content - staggering work Sir, even with the spoiler issue! Love your YouTube channel. You should do more links from here to get your views up. That car sounds bl00dy amazing!

Keep up the top work.
Thank you. I need to try and get a decent Youtube video together with some proper action while the weather is good. I did throw a little clip up on TikTok yesterday and it seems to have hit the algorithm jack pot, 110k views in 24 hours, 10k likes. Certainly better than a couple hundred on YT.

https://www.tiktok.com/@escygt/video/7121402055842...

Escy

Original Poster:

3,960 posts

151 months

Monday 18th July 2022
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Bright Halo said:
Really like the look of the spoiler!
Not sure about the headlamp surrounds though?
I'm not sure yet either.

Gtom said:
Fair enough, I just thought it might have been a nice nod to the Carerra GT considering it’s mid engined, silver and has nearly as much power.

Maybe I’m just a bigger chav than I thought!
I'm quite liking flat foot shifting so I'll see if I can burn through the clutch in a couple thousand miles to give a nod to the Carrera GT. smile

Escy

Original Poster:

3,960 posts

151 months

Monday 22nd August 2022
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The last piece of the Sport Design bodykit was the front corner splitter parts. I've definately been ripped off by the first place I ordered them from. I ordered from again, this time from Design911 and got them about a month later. I took the bumpers off and took them to a body shop. It took them about 2 weeks to get them painted.

Bumpers off, you can see the big old air filter hiding in the corner.

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Got them back

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There was an exhaust trim piece that I was missing from the rear bumper, after a long phone call to my local Porsche dealership it was available. They relieved me of £200 for it but I'm glad I could get it as it adds strength to the bumper and it was bugging me.

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When I had the front bumper painted I got them to flush the holes where the number plate plinth was. I'm using magnets to hold the number plate on now which I think is a nice solution, easy to remove it when I want for a cleaner look.

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Little video showing the plate fitted and removed.

https://www.tiktok.com/@escygt/video/7134248730139...

Some photos. The colour match is good, I'm pleased with how it looks. I might paint the diffuser style bit black in the future. I saw a photo of someone who had done but it was after my bumpers were painted. Think it looks good.

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Escy

Original Poster:

3,960 posts

151 months

Monday 22nd August 2022
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gregs656 said:
Looks great. I see the Cayenne still doing the business too.
It's been putting in work lately. It's such a great vehicle. I love it but I don't love the 13.7mpg it's averaged over the last 1500 miles though.

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Bright Halo said:
Looking really good!
I’m still amazed at your mechanical engine swap work. I have a standard 986 s and there appears next to no room to work on the engine so how you have done this is just mind boggling.
Great car
You are correct, there is next to no room to work on a flat 6. They are huge lumps. Most jobs I find are difficult on those engines. I've got plenty of room in my car though. There's good access all around the engine, I can get to the front and both sides from underneath. There are no bulky subframes in my way. Often engine swaps are a pain with random simple jobs being loads of work or requiring the engine out.

I think nearly every single maintenance job is easier than either working on the 2.7T in an Audi or a flat 6 in a Porsche. I can change turbos without pulling the engine, change the cambelt easily, spark plugs in 10 minutes. I've got lucky from a maintenance aspect which is just as well as it's required a fair amount of it!