Phoenix from the flames - Porsche Boxster with an Audi 2.7T
Discussion
Things are moving forward, i've stripped off all the parts I needed from the Audi and sold a load of bits. I needed to get rid of the shell so I can get the Porsche in the garage.
I usually use a company with a hiab to lift shells off my drive but they were messing me about so I had to use someone else and it was going to be a drag it out job. This was a challenge. I bought some skates that you sit the wheels on to move cars about with, I don't have any wheels for it as I sold them but I've got a really sturdy pallet that's pretty wide so I put this on the skates and dropped the shell onto it. The front end I sat on my engine hoist. We then winched it up the driveway.
This didn't go smoothly, 2 wheels snapped on each of the skates under the pallet, these are apparently good for 450kg each but I guess you need a perfectly smooth floor. We just dragged it on the pallet from that point as there was not much choice. Once the shell was clear of the drive a wheel broke on my engine hoist. Luckily by that point he was able to reverse up and just winched it straight onto the truck.
Here are the casualties. That's the second wheel that's broken on the hoist but I do badly abuse it so it's fair enough. Those skates on the other hand I don't think are up to much. Another Chinese ebay special.
The guy that collected it had a decent recovery truck, only a few years old so I was surprised he's willing to drag scrap onto it. I don't think I would.
I've finally got the Porsche in the garage which is a relief as there is a fault on the central locking, it locks and then immediately unlocks so it's just been sat on the drive unlocked (which is why the bonnet isn't fully closed in the photo). I've ordered a diagnostic cable which should read the alarm module so I can diagnose the fault. The plan now is to see if I can fix the tapping on the Porsche engine. If I do repair it i'd like to MOT it and run it daily for a few weeks before starting on the engine conversion.
I usually use a company with a hiab to lift shells off my drive but they were messing me about so I had to use someone else and it was going to be a drag it out job. This was a challenge. I bought some skates that you sit the wheels on to move cars about with, I don't have any wheels for it as I sold them but I've got a really sturdy pallet that's pretty wide so I put this on the skates and dropped the shell onto it. The front end I sat on my engine hoist. We then winched it up the driveway.
This didn't go smoothly, 2 wheels snapped on each of the skates under the pallet, these are apparently good for 450kg each but I guess you need a perfectly smooth floor. We just dragged it on the pallet from that point as there was not much choice. Once the shell was clear of the drive a wheel broke on my engine hoist. Luckily by that point he was able to reverse up and just winched it straight onto the truck.
Here are the casualties. That's the second wheel that's broken on the hoist but I do badly abuse it so it's fair enough. Those skates on the other hand I don't think are up to much. Another Chinese ebay special.
The guy that collected it had a decent recovery truck, only a few years old so I was surprised he's willing to drag scrap onto it. I don't think I would.
I've finally got the Porsche in the garage which is a relief as there is a fault on the central locking, it locks and then immediately unlocks so it's just been sat on the drive unlocked (which is why the bonnet isn't fully closed in the photo). I've ordered a diagnostic cable which should read the alarm module so I can diagnose the fault. The plan now is to see if I can fix the tapping on the Porsche engine. If I do repair it i'd like to MOT it and run it daily for a few weeks before starting on the engine conversion.
Escy said:
I've finally got the Porsche in the garage which is a relief as there is a fault on the central locking, it locks and then immediately unlocks so it's just been sat on the drive unlocked (which is why the bonnet isn't fully closed in the photo). I've ordered a diagnostic cable which should read the alarm module so I can diagnose the fault.
Fingers crossed its something simple. Could be as simple even as a failed door switch. Most central locking issues tend to be the drivers side locking motor. I've taken that out, opened it up, checked it for dry solder joints, cleaned the micro switches, etc. Can't find anything wrong. I noticed the passenger side sounded funny, took that one apart and there was a load of dust inside from one of the motors. I thought i'd found the problem. I swapped the electrical section from the one in the Audi over. It works fine but still locks then unlocks. Decided to put the Porsche one back in with the motors from the Audi one fitted to it. Works fine, the problem is still there. The car locks and unlocks 2 seconds later and the alarm beeps twice so it knows there is a problem. The window drop function is fine, the interior lights come on when you open either door, or boot.
Escy said:
I've finally got the Porsche in the garage which is a relief as there is a fault on the central locking, it locks and then immediately unlocks so it's just been sat on the drive unlocked (which is why the bonnet isn't fully closed in the photo).
Sounds familiar - one of the guys at work has a 986 Boxster and I'm pretty sure he had a similar problem not too long ago. I think he ended up getting it sorted by his local Porsche dealer. I'll check with him next week to see if he can shed any light on the possible cause 
LanceRS said:
Just a suggestion, does the car think that one of the doors is still open and therefore won't lock? I'm pretty sure that with some BMWs the central locking does that if a door is not closed properly.
Morning! Long time lurker, first time poster, and So hoping that Turbo Boxster v2.0 goes much better for you.As LanceRS said - without the bonnet latched shut, the car won't lock properly. If you're worried to try it with the bonnet closed in case you can't open it again, there should be an emergency release cord inside the front bumper which you can reach (I think) with the o/s headlamp removed so if you do that first, you'll have an easy backup plan.
Best of luck with the build
As above, my car will not lock with a door open (it flashes to say it has locked, and then immediately un-locks, no beep or anything...) so have you tried sitting in the car with the doors and bonnet closed, and then locking the car?
I will have a go tonight, see if mine un-locks if I leave my bonnet open.
I will have a go tonight, see if mine un-locks if I leave my bonnet open.
Checked with my colleague at work, apparently in his case the garage fixed it by replacing the passenger side door lock - perhaps the microswitch was faulty on his car. I see that you've already ruled out any faults with the door locks and microswitches though. He also mentioned that the first place the garage looked was the passenger door ECU, which apparently is under the carpet on the floor behind the seat and has a tendency to get wet if the floor is leaking... in his car it was fine, but perhaps it's worth checking yours if you haven't already? Could be something simple like a corroded connector stopping the signal from the microswitch reaching the ECU?
I started working on the Boxster, trying to sort out the engine noise which I thought was a duff hydraulic lifter. It's the first time i've worked on a flat 6 engine inside a Boxster, I didn't enjoy it at all there's not much space. I bought a (s
t ebay) kit with all the timing tools for the M96 engine, the tool to lock the crankshaft only fitted with the handle removed and the tool to set the cam positions doesn't even fit inside a Boxster engine compartment. That made the job harder than it should be.
I took the exhaust manifold off to give myself better access. I knew this was a risky move, the bolts snap easily, I was careful, working them back and fore with loads of WD40, I still managed to snap two. I drilled one out and used a pretty handy tool that's grips like a drill chuck on the other. I couldn't get my drill in on the one that I drilled out so needed to use an extension that wobbled all over the place. I've included a photo of me drilling it out as considering i'm on my back with swarf dropping all over me and the drill extension was shaking all over the place it was a minor miracle I managed to get it bang in the middle of the bolt.
You can see all the oil on the cylinder 2 exhaust port, I think it's probably got stuck pistons rings from where it was sitting for a year, i've seen people use various potions to try and free them up but on a flat engine it's not going to work. I carried on with the lifters. I did find one that wasn't holding oil pressure like the others, I could easily compress it so I changed it, put it all back together but the noise remains. So it was a waste of time (and it took me a long time). If it was a normal engine i'd have pulled the cylinder head and sump off and got the piston out but to go that on a Porsche engine you need to split the crankcase.
I'm putting the Porsche on the back burner for a while, a Celica 190 (2ZZ-GE engine) came up for sale locally at a price I couldn't ignore. I'm going to break it for parts and stick the engine in a MR2. I'll start a new build thread for that. I've built a few in the past and I think they are fantastic. I actually have more enthusiasm to build an MR2 2ZZ than I do for the Porsche at the moment. That's a bit of worry to be honest.
I had to make space for the Celica which means moving the Porsche to the back of the car port. That's easier said than done with all the engines and gearboxes i've got taking up all my space. I managed to scratch the Porsche during the process, even though I was only pushing it. That's left me frustrated.
t ebay) kit with all the timing tools for the M96 engine, the tool to lock the crankshaft only fitted with the handle removed and the tool to set the cam positions doesn't even fit inside a Boxster engine compartment. That made the job harder than it should be.I took the exhaust manifold off to give myself better access. I knew this was a risky move, the bolts snap easily, I was careful, working them back and fore with loads of WD40, I still managed to snap two. I drilled one out and used a pretty handy tool that's grips like a drill chuck on the other. I couldn't get my drill in on the one that I drilled out so needed to use an extension that wobbled all over the place. I've included a photo of me drilling it out as considering i'm on my back with swarf dropping all over me and the drill extension was shaking all over the place it was a minor miracle I managed to get it bang in the middle of the bolt.
You can see all the oil on the cylinder 2 exhaust port, I think it's probably got stuck pistons rings from where it was sitting for a year, i've seen people use various potions to try and free them up but on a flat engine it's not going to work. I carried on with the lifters. I did find one that wasn't holding oil pressure like the others, I could easily compress it so I changed it, put it all back together but the noise remains. So it was a waste of time (and it took me a long time). If it was a normal engine i'd have pulled the cylinder head and sump off and got the piston out but to go that on a Porsche engine you need to split the crankcase.
I'm putting the Porsche on the back burner for a while, a Celica 190 (2ZZ-GE engine) came up for sale locally at a price I couldn't ignore. I'm going to break it for parts and stick the engine in a MR2. I'll start a new build thread for that. I've built a few in the past and I think they are fantastic. I actually have more enthusiasm to build an MR2 2ZZ than I do for the Porsche at the moment. That's a bit of worry to be honest.
I had to make space for the Celica which means moving the Porsche to the back of the car port. That's easier said than done with all the engines and gearboxes i've got taking up all my space. I managed to scratch the Porsche during the process, even though I was only pushing it. That's left me frustrated.
I've been reading this thread over a Sunday morning coffee having spent a carless 6 months in Hong Kong, thinking 'wow I miss having a garage..and a car...and doing this sort of thing" (I built a h22 civic, did a lot of work on the S2000, including breaking at the end of its life, had a chimaera - need I say more..).
and then I got to this bit:
God speed to you sir, and PLEASE don't give up on the Porsche..
and then I got to this bit:
Escy said:
I took the exhaust manifold off to give myself better access. I knew this was a risky move, the bolts snap easily, I was careful, working them back and fore with loads of WD40, I still managed to snap two. I drilled one out and used a pretty handy tool that's grips like a drill chuck on the other. I couldn't get my drill in on the one that I drilled out so needed to use an extension that wobbled all over the place. I've included a photo of me drilling it out as considering i'm on my back with swarf dropping all over me and the drill extension was shaking all over the place it was a minor miracle I managed to get it bang in the middle of the bolt.
And all of a sudden, I don't ever want to see the underneath of another car again, unless its pristine and on somebody else's lift.God speed to you sir, and PLEASE don't give up on the Porsche..
I finished the MR2 2ZZ swap and now that's my daily driver.
The plan was to start on the Boxster once the MR2 was done but I got side tracked by another Audi A6 2.7t that came up locally for a bargain price. I decided to buy it and break it for parts as there was a few things I needed. It had a re-map and dyno print out for 290bhp, it went well. It had done 125k miles, the same as the silver A6 i'd bought, I decided going to use this engine as the code is AJK which is the same as the one I used in the last Boxster so the wiring has all been worked out. It had been worked on by some right animals in the past, everything seemed to have half the amount of bolts fitted, headlights cabled tied in, water hose kinked so bad the oil cooler wouldn't have been doing anything, etc. I removed the engine in the garage and then dragged it outside to with my black MR2 (now sold) to get the rest of the parts off I wanted (it had a nice set of Recaro's).
So now it's time to start on the new Boxster build.
The plan was to start on the Boxster once the MR2 was done but I got side tracked by another Audi A6 2.7t that came up locally for a bargain price. I decided to buy it and break it for parts as there was a few things I needed. It had a re-map and dyno print out for 290bhp, it went well. It had done 125k miles, the same as the silver A6 i'd bought, I decided going to use this engine as the code is AJK which is the same as the one I used in the last Boxster so the wiring has all been worked out. It had been worked on by some right animals in the past, everything seemed to have half the amount of bolts fitted, headlights cabled tied in, water hose kinked so bad the oil cooler wouldn't have been doing anything, etc. I removed the engine in the garage and then dragged it outside to with my black MR2 (now sold) to get the rest of the parts off I wanted (it had a nice set of Recaro's).
So now it's time to start on the new Boxster build.
I've been thinking it over and i've decided on the plan of attack for this car. Although pretty much everything related to the engine conversion on the car that caught fire is salvageable, I can't afford to replace all the parts that got destroyed at the moment. I'm going to mothball the bits I have got and look to build another Boxster again in the future (once i've got a house sorted).
The plan this time is to use a completely standard 2.7t engine. I'll use the standard turbos, injectors, downpipes, etc. This should be good for around 350bhp with a re-map, not amazing but enough to be fun and not far behind the Cayman GT4 (380bhp) .In the future, a set of injectors and bigger (K04) turbos would see it make 450bhp so it's got some potential.
I'll use the Boxster 5 speed gearbox. I'll know from offering up the standard engine on the last car that the turbos will foul the body so i'll have to cut and weld where required. I've not made a decision yet on if i'll use intercoolers like the Audi did or if i'll go for air to water charge cooling (it was expensive last time and a lot of work), I could even opt for just running water/meth injection.
The benefits of keeping it all OEM is it should be reliable. The downside is the 2.7t is a total pig to work on, you can see how tightly packed everything is. Everything is caked in oil, every 2.7t i've seen has been the same.
Pulling the original engine out of the Boxster.
The gearbox in the background is a Cayman S 6 speed, that's what I had in the last car. You can see there is a big difference in size.
The plan this time is to use a completely standard 2.7t engine. I'll use the standard turbos, injectors, downpipes, etc. This should be good for around 350bhp with a re-map, not amazing but enough to be fun and not far behind the Cayman GT4 (380bhp) .In the future, a set of injectors and bigger (K04) turbos would see it make 450bhp so it's got some potential.
I'll use the Boxster 5 speed gearbox. I'll know from offering up the standard engine on the last car that the turbos will foul the body so i'll have to cut and weld where required. I've not made a decision yet on if i'll use intercoolers like the Audi did or if i'll go for air to water charge cooling (it was expensive last time and a lot of work), I could even opt for just running water/meth injection.
The benefits of keeping it all OEM is it should be reliable. The downside is the 2.7t is a total pig to work on, you can see how tightly packed everything is. Everything is caked in oil, every 2.7t i've seen has been the same.
Pulling the original engine out of the Boxster.
The gearbox in the background is a Cayman S 6 speed, that's what I had in the last car. You can see there is a big difference in size.
Escy, I'm one of the many that donated in the hope to see this projected reborn.....
If it were my choice in the first place, this is exactly what I wanted you to do!
Please take a million pics of everything and what you need to cut etc. as this genuinely excites me. I'd much prefer to see this as it's within the reach of mere mortals like myself
Good luck!
If it were my choice in the first place, this is exactly what I wanted you to do!
Please take a million pics of everything and what you need to cut etc. as this genuinely excites me. I'd much prefer to see this as it's within the reach of mere mortals like myself
Good luck!
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