Phoenix from the flames - Porsche Boxster with an Audi 2.7T
Discussion
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.
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.
P6251381I'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.
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.
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.
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. 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'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 said:
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).
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 compressorroadie 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. 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. have always found tin compression ones very hit and miss in my limited experience.
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.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 
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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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.
P2021127The carbon fibre spoiler, nicely made and was a fairly reasonable price (until my Brexit bonus added £150 onto it)
P2021131You'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.
P7121402I 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.
P7141405Stripped the spoiler mechanism apart, there's quite a bit going on here.
P7141403I repaired this and now it all works fine.
P7141404This is how it looks, spoiler down.
P7161407P7161408The spoiler up.
P7161410P7161409One 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.
P7161411The headlights were looking a bit cloudy I took them out to polish them.
P7011392In 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.
P7161412I 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.
P7161413Fitted. 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.
P7161414P7161415Definitely 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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They look decent without the centre lock cover. I might try that look at some point.
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