I'm not trying to advertise on purpose. Someone asked, and I replied. Also, as I stated earlier in this thread, if a moderator thinks I am out of line, they can contact me and I will be happy to talk to them about becoming a paid advertiser. To date, I have not posted my company's name or contact information, and there is nothing in my signature or "screen name" that is specific to my company. This was done on purpose as I did not want to get accused of advertising. I started this thread for informational purposes.

Advertising or not, keep the updates coming! This is a great project and I very much enjoy following it. Good luck with the rest of the project.

SB

Indeed, looking forward to how this project unfolds. Very cool!

Yeah i think this project is very interesting.

I would like to hear a sound clip, or see a video clip when your done.

I wonder how an exhaust like that will sound???

The wiring harness has been reduced to only what is needed to make the engine run.... hopefully.

http://i180.photobucket.com/albums/x...z/IMG_5776.jpg

And here's what wasn't used...

http://i180.photobucket.com/albums/x...z/IMG_5778.jpg

Are you planning to have ABS? Are you going to use the stock instruments?

Yes to the ABS. I have no intentions of removing the ABS system and atleast in the Subaru engine management, the ECU does not control the ABS system... although it does control the cruise control (which I obviously won't have in this car)

How's the project coming? That wiring harness makes my head hurt.....amazing how much stuff isn't needed to make a car run.

SB

I'm working on the custom fiberglass roof scoop that will feed air to the intercooler in the rear trunk. Should have some pictures to share in a few days.

NOW we are talking!

I got the first round of primer sprayed on the prototype fiberglass roof scoop. Once I'm happy with the shape and finish, I'll make a mold off of this part. The plan is to make the scoop removable so I can get to the rear trunk and remove the fiberglass hard top to get to the top of the engine. Also, now that most of the rear window will be blocked, I will probably just fill it in and mount a rear facing camera somewhere and an LCD display where the rear view mirror would go.

I know the shape of the scoop may not be the most attractive, but it will definetly serve it's purpose of getting a lot of cool air to the intercooler which will be in the rear trunk and will vent down over the transaxle and through the license plate are in the rear bumper.

http://i180.photobucket.com/albums/x...z/IMG_5785.jpg
http://i180.photobucket.com/albums/x...z/IMG_5788.jpg
http://i180.photobucket.com/albums/x...z/IMG_5792.jpg
http://i180.photobucket.com/albums/x...z/IMG_5789.jpg

Zoinks!

Will that be part of the kit too ? ;)

That scoop just says, "I'm going so fast I don't care if I can't see anything behind me!"

das ist ein porsche; ve use zee vhale tails for the movink of zee air into zee intercoolink device.

still digging the rear flares - did you fab those or buy them somewhere - i'd love a set (run some big wide 911 turbo rims); much of a job cutting back the quarters or fabbing around the rear bumper?

I really like what he has done!!! I still deal with the BS of people ********************ing about advertising.. I guess those people don't have a Television and don't notice that EVERYTHING is an advertisement for something. Welcome to the 21st century.

The Boxster/ Suby conversion makes lots of sense to me... Even though I am no fan of the German car with a Japanses engine, the suby engine is a real powerhouse.

Done right this conversion could be the key for those who want big power and aren't worried about keeping the car Porsche powered.

Looks like a Mohawk.

I would have put something like a whale tail.

But i guess a roof scoop will be more efficient.

or twin scoops with the intakes up beside the hardtop just behind the side window. Could keep the back window that way.

There's no way I would do any sort of whale tail on a Boxster. I know the roof scoop won't be the most attractive thing to some people, but IMO, something like a whale tail on a mid-engine car would be even worse. Not only that, but with the factory style hard tops, the aerodynamics just wouldn't work. The Boxster roof lines don't have the gradual sloping line that the 911's have which feeds air directly to the louvers in the whale tails. Instead roof sharply drops off, which will cause the air to be turbulent right behind the rear glass and give poor flow to the intercooler mounted horizontally.

As for the "twin side scoops" idea mentioned. The problem with this is that unlike the Toyota MR2's, the Boxster has the convertible clamshell right behind the seats, and the engine bay is completely different as well.

The whole idea of this roof scoop design was to make it easy to install and quickly remove for the end user. Sure I could have made a complicated Zeintop looking contraption that would be more aesthetically pleasing, but this is intended to be used on race cars where the pieces need to be easily removable for engine and interior access. Not only that, but if the part becomes too complicated, the price may become too high for most people to justify... especially since they will also need to buy a hard top anyway. It's not always about making the perfect part. sometimes you have to factor in compromises for other systems or requirements.

What's happening, kcpaz?

I have a few customer jobs I need to finish up before I can spend any more time on this car. Probably get back on it in a few weeks.

Really like the project, but you lost me on the dorsal fin. Must you go that extreme?

HOLY COW!!! HOW AM I JUST SEEING THIS NOW?!

Amazing project. I too would be interested to see a full kit +harness (minus the powertrain)!

Keep up the good work, and please keep us posted. What size turbo are you running? I'm curious how tuning will be achieved- will you be using the stock ECU? :cheers:


FWIW: I am doing a GC8 STI swap
:cheers:

I like the concept but would rather it be more stealth. the freaky mowhawk thing doesn't work for me. but I'll watch with interest...

Guys, this roof scoop configuration is designed for race cars only where I will be needing a large amount of fresh, cool air to feed to an air-air intercooler that will be mounted in the trunk. This need for air trumps the need to be aesthetically pleasing in every way. For street cars or more mild builds with different goals, an air-water intercooler will be mounted in front of the engine and a heat exchanger will be used to keep it cool. Whether you like the look of the roof scoop or not doesn't really matter because to me, it's more important to cool the charged air going into the engine, and for this specific car and it's application, an air-air intercooler is the best way to do this.

For engine management, I'm using the stock Subaru ECU and modified wiring harness, and will be doing an open source tune.

I like the roofscoop--It is made to function. Is it possble to install a 12x12 submarine type window in the back of that thing?


Are you going with EL headers? I would be super curious to hear an UEL header on that beast! it sure would surprise the hell out of me with its intoxicating rumble.

The headers aren't perfectly equal length so there will still be some "runble" to the exhaust.... and when the wastegates open, the thing will sound like hell :D

how did you determine the minium size of the intake and what were your goals as far as optimum output? Seems like a very technical exercise to get it in the sweet spot.

I agree, it's always fun to have options out there! I love my Boxster, and having the potential for both a Suby engine or Corvette LS engine is great!

Heck in my old VW days I still remember one of the coolest swaps I'd ever seen was a Cadillac 32v Northstar V8 shoe horned into an early 90's MKII Golf. Nowadays the diesel TDI engine is finding it's way into many applications, including Jeep YJ's.

Excitement through experimentation leading to application!

Quick update...

The plan was to finish the intercooler plumbing before doing the cage to make things easier... but I couldn't help myself. The cage isn't done yet (still have harness bars to add and final welding) but it's pretty close. I'll throw up some better cage pictures once everything is completely finished...


http://i180.photobucket.com/albums/x...z/IMG_6310.jpg
http://i180.photobucket.com/albums/x...z/IMG_6311.jpg
http://i180.photobucket.com/albums/x...z/IMG_6312.jpg
http://i180.photobucket.com/albums/x...z/IMG_6313.jpg

I made a custom intercooler for the trunk and started the "duct-work" to direct the hot air out the rear bumper. The last shot shows the bottom of the duct open. This will be closed off to force the air out behind the car rather than randomly under the car. I'm just waiting to pull the engine/tranny to finish everything off. You can see the turbo dumps directly into the intercooler on the driver's side, then shoots off into the engine bay on the passenger side. The plumbing will be VERY short and direct. I was going to use Wiggins clamps, but then reminded myself that this is supposed to be a "budget build" :) The intercooler core measures 18" x 12" x 4.5" with 2.75" inlet/outlets


http://i180.photobucket.com/albums/x...z/IMG_6314.jpg

http://i180.photobucket.com/albums/x...z/IMG_6315.jpg
http://i180.photobucket.com/albums/x...z/IMG_6316.jpg
http://i180.photobucket.com/albums/x...z/IMG_6317.jpg
http://i180.photobucket.com/albums/x...z/IMG_6319.jpg

http://i180.photobucket.com/albums/x...z/IMG_6321.jpg

http://i180.photobucket.com/albums/x...z/IMG_6324.jpg

nice jungle gym!

Man, I wish I had your resources and knowledge. That looks like more fun than a man should be legally allowed to enjoy!

Nice work! Definitely one of the coolest Boxster projects I've seen to date.

Intercooler plumbing finished. That's it. Only one short section of tube on the cold side. The hot side is just a 2"-2.75" coupler from the turbo to the intercooler so no plumbing there. The engine and transmission are now out so I can do all of the engine service work (TGV delete, gaskets, injectors, fuel rails, leak-down test blah... blah...) and install the flywheel. The next time the engine goes in the chassis will be to try and start it. Time to finish the cage, do the body work, and paint the thing...


http://i180.photobucket.com/albums/x...z/IMG_6392.jpg
http://i180.photobucket.com/albums/x...z/IMG_6396.jpg
http://i180.photobucket.com/albums/x...z/IMG_6398.jpg
http://i180.photobucket.com/albums/x...z/IMG_6399.jpg
http://i180.photobucket.com/albums/x...z/IMG_6401.jpg

Air-Jacks added...

http://i180.photobucket.com/albums/x...z/IMG_6509.jpg
http://i180.photobucket.com/albums/x...z/IMG_6510.jpg

sooooo jealous!! I want air jacks in my 944. I just can't justify them when they are worth as much as the rest of the car.

Oh... and that cage is beautiful!!

I've been waiting for a kit like this to become available for a couple years now. Subscribing to this thread. Wonderful fabrication work.

So one of the things I have been dreading ever since I decided to run the wide body GT2 front end is the radiator duct situation. There are two ways to go about it, the expensive way, and the time consuming way. I chose the latter for two reasons. The first reason is the cost of converting the radiators and related duct work to the Turbo/GT2 spec. Basically, that would mean all three turbo 996 radiators, GT2 air ducts for all 3 radiators, radiator mounting brackets for all 3 radiators, and matching cooling lines along with other misc. hardware. Yeah, it's expensive... like a few thousand dollars. Not in the budget for this car. The other reason I decided to stick with the stock Boxster radiators is I want to be able to test the cooling capabilities of the stock Boxster cooling system with the extra horsepower and potential heat that the turbo motor might create. So here is what I came up with...

http://i180.photobucket.com/albums/x...z/IMG_6643.jpg
http://i180.photobucket.com/albums/x...z/IMG_6645.jpg
http://i180.photobucket.com/albums/x...z/IMG_6646.jpg
http://i180.photobucket.com/albums/x...z/IMG_6651.jpg
http://i180.photobucket.com/albums/x...z/IMG_6528.jpg


The side radiators are in the stock location using the stock mounting brackets. The center radiator mounts upside down using a slightly modified stock mounting bracket and the stock plastic duct. In stock configuration, the Boxster S and 996 radiator would vent down below the car through holes in the bottom of the bumper cover. Aerodynamically this is less than ideal which is why the GT3, RSR and GT2's vent up through a hole on the top of the bumper cover. What this means is I had to move the center radiator forward and angle it up to make room for some duct work that would direct the air up instead of down.

Great stuff, kcpaz. Keep it coming! :cheers:

Plumbed the air-jacks and started on the electronic power steering conversion. Both are almost finished, just need to get a few more fittings.

http://i180.photobucket.com/albums/x...z/IMG_6818.jpg
http://i180.photobucket.com/albums/x...z/IMG_6819.jpg
http://i180.photobucket.com/albums/x...z/IMG_6821.jpg