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

[Escy]

Yeah, not far off now.

[Janosh]

I assume the the Kaaz is a plated diff?

Might be worth trying some Castrol Syntrax (I use 75w-140), seems to work well with plated diffs that tend to be clunky. I certainly wouldn't be using ordinary engine oil with some modifier.... the diff won't last long!

[chuntington101]

Once it's all buttoned up you just need some TTE650 turbos!

Cracking worknas ever. Any pics of the intercoolers in situe?

[Escy]

Janosh said:

I assume the the Kaaz is a plated diff?

Might be worth trying some Castrol Syntrax (I use 75w-140), seems to work well with plated diffs that tend to be clunky. I certainly wouldn't be using ordinary engine oil with some modifier.... the diff won't last long!

Yeah, it's a plated diff. I went on recommendation of Opie oils, to use the correct grade oil for the gearbox and add the friction modifier to make the LSD work.

chuntington101 said:

Once it's all buttoned up you just need some TTE650 turbos!

Cracking worknas ever. Any pics of the intercoolers in situe?

I'd like to upgrade the turbos, I don't think I'm a fan of the power delivery on the K03's, they run out of puff early. I'll get some photos of the charge coolers this weekend.

[chuntington101]

What sort of power can the 2.7s make before you need to start throwing big money at them (internals, etc.)?

[Escy]

My understanding is they are good for 450bhp to 500bhp on standard internals, past that the weak spot becomes the conrods. With a set of rods you are good for about 600bhp.

[Escy]

I tried to take a few photos of the charge coolers, it's hard to get a decent photo of them as it's all very tight inside the engine bay. When it's next on a ramp i'll be able to get a decent photo from underneath.

[J44Y]

I've just found this thread and i'm very excited. I saw it ages ago with the previous build and was sad to see the fire. But didn't know you'd gone for round 2!

Since then i have purchased a 3.2S Boxster myself that was a Cat D and have put it back on the road (only needed a bumper and front crash bar, we think something dodgy was going on at the inspection place as they'd even washed it... who washes a written off car...). It has 189k on the clock so this is exactly what i want to do when it eventually goes pop!

[Escy]

189k is good going on the original engine. If you do eventually go Audi power, I want to see some photos.

[Terror Factor]

Following this with huge interest! This swap makes so much sense. It should make such an awesome car!

I prefered the previous supercar slaying idea to using the stock stuff, but that's easy to say if you aren't paying for the parts of course!
Really curious to see the result!

If we hadn't these silly tuning laws in Belgium and insanely high taxes based on cc and emisions (although a 2.7 should be doable, around 1000gbp a year), this could be the car I'd actually spent money on. And I am a cheapskate!

Keep it up! Glad you didn't give in after the previous mishap

[Escy]

I wish I could have gone for supercar slaying power again but I know how much it cost me the last time (about 4x more than this car).

I've still got most of the parts from the fire damaged car (exhaust, wastegate, turbo, gearbox with a Quaife, etc). I want to build another in the future and perhaps i'll use a different engine from the VAG stable, i've got a silly idea

I haven't been driving my Boxster yet, i've been too busy/lazy watching football and drinking beer. I'm going to start using it to commute to work next week and then on the weekend i'm going to meet up with some guys on the Boxa forum for a road trip around South Wales which should be good fun.

[Escy]

It's been really hot lately, I was keeping an eye on the inlet air temperatures, when cruising I am seeing around 50c and ambient was around 25c, not good, I don't know what I am getting when booting it but it'll be bad and explain why it feels flat at the top end.

I know the way i've set up the charge cooler system isn't ideal, the engine bay is like an oven and has really poor airflow, even by mid engine standards. I've got all my charge coolers bits fitted inside the engine bay (header tank, water pump and 2 heat exchanger cores with the radiator bellow the engine). I was amazed I could fit it all in to be honest but it does mean even some simple maintenance will be an issue, i've barely got any space left.

This is how the radiator sits


I decided to add a shroud to the radiator to improve airflow


The shroud worked too well, at about 50mph it flipped the radiator so the shroud ended up facing backwards. I didn't have any tools to had to work it back and fore to snap it off so I could get home. The radiator amazingly didn't leak but it's all bent out of shape. In hindsight I should have seen this happening.




I'm unsure where to go at this point. The current system is flawed, it all heat soaks inside the engine bay and like I mentioned, maintenance will be an issue in the future. I could replace the radiator, improve the brackets holding it and make another shroud, it could work well but it's in a vulnerable position anyway so I won't bother. I can fit a radiator at the front (get a Boxster S centre radiator and use it for the charge cooler).

I have just bought a cheap used AEM water/meth injection setup. I'm thinking about ditching the charge coolers completely and running the water/meth pre-turbo. I'd like to ditch the inlet Y pipe, run an air filter for each turbo and move the MAF post turbo.

Whatever happens probably won't be for a while now.

[Peanut Gallery]

Random idea.. Fit the radiator horizontally about where it is now, and fit another shroud that pushes air up through the rad and into the engine bay? Some narrow straps from the floor of the car to the bottom of the shroud should keep it from being pulled down at speed, and you get more, albeit hot, air through the engine bay? New shroud does not have to be connected to the radiator, so if it does meet a brick and is removed you can continue?

[Mezzanine]

Would some small holes or slats in the shroud stop to air pressure building up inside it? You might lose a bit of additional wanted air to the radiator but it might be better aerodynamically?

[Escy]

Both good ideas but I think i'm done with the charge cooler set-up, I don't want to buy another radiator for it, I might try bending my current one back into something that resembles flat and try another shroud but it'll just be a stop gap now i've got water methanol injection on my mind.

[ATM]

Am I the only one thinking I'd want this in a 996 coupe?

[gofasterrosssco]

I think the front mounted CC rad is really the best and most reliable option, and the most likely to deliver the required cooling performance. Either a central one at the front (which you mentioned) or two smaller rads in front of the existing engine radiators. Benefit being you can link them all serially should one be insufficient.

A properly sized radiator with a good pump (and crucially, free of air) should cope fine with your power levels, assuming the CC's themselves are at least of reasonable quality..

[chuntington101]

Agree with above. Has to be the best way! Need as much low temp rad as you can get!

Also I think fitting the old turbo and intercooler in a compound would help, with IATs (and power)!

[CrashBang]

For cooling try using the Boxster S / 996 front centre rad solution, its cheap and tested - Couple it with the 996.2 GT3 mounting bracket, you will need to modify the front bumper slightly but it will improve the airflow.

Also mesh your front grills to stop leaves and debris, removing the a/c condensers, as you have, improves airflow significantly.

Take a look at this link which shows details

http://kellyanneporsche.com/emmy.htm#Cooling

[phalanxs]

There has been tesing on a Subaru for a meth injection + no intercooler setup, and it was shown to be not as good as an intercooler alone.