2002 Boxster S - up spec overhaul for Le Mans duty
Discussion
Noises are being made about Le Mans so I had a look at the Boxster and made a list of things I want to do before then, funds permitting!
This weekends project was swapping over the steering wheel for something a bit nicer. I’ve never really gelled with the 996/986 wheel - although it’s a nice rim thickness I just find it a bit uninspiring to hold. Maybe it’s because it was their early attempt at an airbag and because I really love the old Porsche 4 spoke wheel with the big rectangular horn pad!
Anyway - I obtained a nice momo wheel which is actually branded Porsche as a motorsport part. The standard wheel comes off very easily after disconnecting the battery and I was also able to swap over a slightly faulty wiper switch that I had had a replacement for since last year.
On reassembly I cut the airbag wires off the old clock spring (leaving the car loom untouched) and soldered in a 3.3 ohm resistor to stop the airbag light coming on. For the horn I found that the brown white wire was the trigger - the brown wire can be isolated as the earthing effect of the steering column is sufficient to trigger the horn. I soldered that to the pin in the back of the momo horn adapter and drilled a hole in the wiper loom plug to accomodate it. Here is a pic half way through - if you look closely you can see the airbag defeat arrangement:
After that it was a simple assembly job but I did have to make a little trim panel to hide the edges of the steering surround as the new wheel is a little smaller there - I just used a bit of thick card with some fabric glued to it and cut it out to make a neat job:
Then the front plate goes on:
And then the wheel itself:
And another one - I think it looks brilliant:
The wheel is slightly further away from the indicator stalk but not much - probably an inch or so. There is a slight stretch but it’s certainly not an issue and will definitely mean I don’t end up catching the wipers if I get involved in any energetic wheel twirling at any point!
The wheel really complements the centre console delete and makes it feel far more sporty in there.
I’d quite like to find an Alcantara gear shift boot and some nice seats next. Hopefully an update soon!
This weekends project was swapping over the steering wheel for something a bit nicer. I’ve never really gelled with the 996/986 wheel - although it’s a nice rim thickness I just find it a bit uninspiring to hold. Maybe it’s because it was their early attempt at an airbag and because I really love the old Porsche 4 spoke wheel with the big rectangular horn pad!
Anyway - I obtained a nice momo wheel which is actually branded Porsche as a motorsport part. The standard wheel comes off very easily after disconnecting the battery and I was also able to swap over a slightly faulty wiper switch that I had had a replacement for since last year.
On reassembly I cut the airbag wires off the old clock spring (leaving the car loom untouched) and soldered in a 3.3 ohm resistor to stop the airbag light coming on. For the horn I found that the brown white wire was the trigger - the brown wire can be isolated as the earthing effect of the steering column is sufficient to trigger the horn. I soldered that to the pin in the back of the momo horn adapter and drilled a hole in the wiper loom plug to accomodate it. Here is a pic half way through - if you look closely you can see the airbag defeat arrangement:
After that it was a simple assembly job but I did have to make a little trim panel to hide the edges of the steering surround as the new wheel is a little smaller there - I just used a bit of thick card with some fabric glued to it and cut it out to make a neat job:
Then the front plate goes on:
And then the wheel itself:
And another one - I think it looks brilliant:
The wheel is slightly further away from the indicator stalk but not much - probably an inch or so. There is a slight stretch but it’s certainly not an issue and will definitely mean I don’t end up catching the wipers if I get involved in any energetic wheel twirling at any point!
The wheel really complements the centre console delete and makes it feel far more sporty in there.
I’d quite like to find an Alcantara gear shift boot and some nice seats next. Hopefully an update soon!
Well I had my first outing of 2019 today in this and had chance to try the new wheel. Oh my goodness what an absolute joy this thing is to drive now!
I can’t believe the difference in tactility with the slightly smaller alcantara rim. And also how small and nimble and direct the 986 feels after more modern cars. Such a fab car.
I’ve been looking at some Fuchs alloys - 17 or 18? They’re very light and will allow me to ditch the sport design ones on there now that for absolutely no reason at all I have fallen out of love with!
I can’t believe the difference in tactility with the slightly smaller alcantara rim. And also how small and nimble and direct the 986 feels after more modern cars. Such a fab car.
I’ve been looking at some Fuchs alloys - 17 or 18? They’re very light and will allow me to ditch the sport design ones on there now that for absolutely no reason at all I have fallen out of love with!
Boxster has been in the workshop over the weekend to investigate a couple of niggles.
The first really, really annoying thing is that in France the alarm chose to be a complete PITA. both keyfobs decided to play intermittent and the alarm kept going off and was very hard to shut up.
A quick chat with my local friendly Porsche dealer revealed that often the roof drains get blocked and that the alarm unit can get wet as it is under the seat.
I was fairly sure my car wasn’t affected by this but I pulled it out to have a look anyway just in case.
Bone dry.
Even the board itself is perfect:
So it’s definitely not that that’s the issue. I suspect that perhaps the aerial is faulty, or maybe both the keys really have decided to be broken! Any ideas?
Whilst I’m at it I will replace the aux belt as I bet that’s not been changed. Inspection reveals it seems perfect but since the seat is out I figure I may as well.
Can anyone help with that alarm issue?
The first really, really annoying thing is that in France the alarm chose to be a complete PITA. both keyfobs decided to play intermittent and the alarm kept going off and was very hard to shut up.
A quick chat with my local friendly Porsche dealer revealed that often the roof drains get blocked and that the alarm unit can get wet as it is under the seat.
I was fairly sure my car wasn’t affected by this but I pulled it out to have a look anyway just in case.
Bone dry.
Even the board itself is perfect:
So it’s definitely not that that’s the issue. I suspect that perhaps the aerial is faulty, or maybe both the keys really have decided to be broken! Any ideas?
Whilst I’m at it I will replace the aux belt as I bet that’s not been changed. Inspection reveals it seems perfect but since the seat is out I figure I may as well.
Can anyone help with that alarm issue?
Something I found when trying to sort one of my faulty keys: -
1.- If the key had gone faulty, the key code must be re programmed on the vehicle computer. This can be done only using a PIWIS tool, available at the dealer or at a qualified Porsche garage.
Try also the following reset:
2.- If you put the battery upside down you risk to short the key remote and break it. When the key fob is flashing slower it means that is not synchronised with the car.
Try also the procedure below:
1.- If the key had gone faulty, the key code must be re programmed on the vehicle computer. This can be done only using a PIWIS tool, available at the dealer or at a qualified Porsche garage.
Try also the following reset:
- turn ignition on,
- turn off.
- remove the transponder from the column
- push any button on the fob within 6 seconds.
2.- If you put the battery upside down you risk to short the key remote and break it. When the key fob is flashing slower it means that is not synchronised with the car.
Try also the procedure below:
- Unlock your car using the key
- Open car door ( if alarm goes off, put key in the ignition to stop the alarm).
- Press unlock button on remote and the remote will resynchronize with the car.
Little update.
I’ve got a pair of new keys on order with Porsche which should fix the alarm issue (I’m told) by my OPC.
In the mean time I changed the aux belt as the one on there hasn’t been changed in my time with the car.
In decent nick really just that tiny bit of degradation in that one place.
Anyway, swapped it out and installed this slightly smaller drive pulley.
From the few exploratory revs I’ve done it seems to have reduced the noise considerably from the non flat six-y twirly bits.
And I’m just dead impressed with myself that I’m preparing for Le Mans like this in October the year before. I mean, organised eh?
I’ve got a pair of new keys on order with Porsche which should fix the alarm issue (I’m told) by my OPC.
In the mean time I changed the aux belt as the one on there hasn’t been changed in my time with the car.
In decent nick really just that tiny bit of degradation in that one place.
Anyway, swapped it out and installed this slightly smaller drive pulley.
From the few exploratory revs I’ve done it seems to have reduced the noise considerably from the non flat six-y twirly bits.
And I’m just dead impressed with myself that I’m preparing for Le Mans like this in October the year before. I mean, organised eh?
edc said:
Try a good Porsche Indy with the PIWIS or PST2 or similar kit. You may find it a bit cheaper.
Thanks for this advice.Picked up 2 new keys from my friendly and helpful OPC and got them coded in by a friend with a laptop.
Now it all works again.
The chap at the OPC was telling me that it is extremely common for the keys to fail, accounting for the majority of problems apart from the ubiquitous drowned alarm issue.
So now I have a running and usable 986 again! Wooo!
Thanks for the help on this issue it was appreciated.
Bit of an update - this car has continued to be perfectly reliable and tremendous fun - it’s getting used more and more and has just ticked over 30k miles.
It was pressed into duty this week at Castle Combe and two of us hammered it around all day - the car was bloody fantastic - never missed a beat and best of all we cured the squealing PFC pads!!! The brakes got super hot obviously but never wilted - RBF600 and the carbon metallic pads - but after the track day I noticed the squeal has totally gone. Thank god for that!!! Two years of it drove mad!
I do have to accept that the M030 suspension isn’t really up to track work. The car moves about too much and the fastest style is very, very smooth and don’t rush the car. Great handling but you can definitely tell you’re in a road car because of the suspension. I am toying with the idea of selling the M030 kit which has now done about 4500 miles and replacing it with some coil overs.
Some great pics on the day from Axel Dowle photographic.
It was pressed into duty this week at Castle Combe and two of us hammered it around all day - the car was bloody fantastic - never missed a beat and best of all we cured the squealing PFC pads!!! The brakes got super hot obviously but never wilted - RBF600 and the carbon metallic pads - but after the track day I noticed the squeal has totally gone. Thank god for that!!! Two years of it drove mad!
I do have to accept that the M030 suspension isn’t really up to track work. The car moves about too much and the fastest style is very, very smooth and don’t rush the car. Great handling but you can definitely tell you’re in a road car because of the suspension. I am toying with the idea of selling the M030 kit which has now done about 4500 miles and replacing it with some coil overs.
Some great pics on the day from Axel Dowle photographic.
This car ferried us up to Croft circuit for a track day with the race car this week - it then spent the whole morning as a support car thrashing round and once again never missed a beat.
However, I am sad to say that after great support from the company the Tarret front top mounts are noisy again. It’s done only about 3000 miles on these - the first set lasted just a few hundred miles - and now they’re clattering away again. I’ll have to replace them at some point but a little disappointing for the price.
Since we seem to be using this for longer distances again now the Euro GT exhaust is getting wearing at 3000rpm. Might have to look at that too.
However, I am sad to say that after great support from the company the Tarret front top mounts are noisy again. It’s done only about 3000 miles on these - the first set lasted just a few hundred miles - and now they’re clattering away again. I’ll have to replace them at some point but a little disappointing for the price.
Since we seem to be using this for longer distances again now the Euro GT exhaust is getting wearing at 3000rpm. Might have to look at that too.
Quick update on this amazing little car. It did another day at Snetterton last week, driven by two of my friends whilst I was busy driving one of the little GDRC race cars.
Again a flawless performance from the Boxster - took us to and from the track, did the full track day - all perfect.
I think what I’m trying to say is that I read so much about the IMS bearing issues on these cars but honestly I think that there is so much fun to be had with them, in exchange for a relatively small risk.
The car is now on 31500 miles and, admittedly the brakes, tyres and those top mounts need attention but otherwise - still - what a car!
Again a flawless performance from the Boxster - took us to and from the track, did the full track day - all perfect.
I think what I’m trying to say is that I read so much about the IMS bearing issues on these cars but honestly I think that there is so much fun to be had with them, in exchange for a relatively small risk.
The car is now on 31500 miles and, admittedly the brakes, tyres and those top mounts need attention but otherwise - still - what a car!
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