Boxster V8

[Nerv]

Good day everyone!

As requested by BC993, some photos of the engine in the car. The scanning is a time consuming process that isn't finished... but I can still give you some shots of the actual car to give confidence in progress.



The dry sump isn't necessary but intake changes and new components that allow for front engine mounting are.

The RHS timing belt cover should be remade anyway, half of the front mounting may be off this cover, because of the extra bosses it has already built in. The alternator and air conditioning mounts may both be redesigned and rebuilt to swap their locations for easier A/C plumbing. This is no small task due to the complexity of the alternator mount because it has the oil cooler and filter assemblies integrated into the mount. Many people get rid of this design but for this specific application the cooler/filter design fits well. If they are redesigned likely the mounting needed for the front will be built into these.

Independent throttle bodies are in the works for the intake, to get the OEM unit to fit without cutting anything it would put the engine/transmission a little low and still there is almost no space for the OEM throttle body. We have both the 4V ABZ and 5V V8's here and although there are some design changes to the 5V that make it a little easier to install, I think with ITB the 4V will still be a better choice. With the length of velocity stacks that will be used and losing the 2 length intake system the torque will drop but max HP will increase thus reducing the strain on the OEM 5 speed transmission. A new flywheel is being designed as well that will accept the 10 bolt crank pattern and actually place the timing ring in the proper orientation for the manual transmission pickup location.

That is it for now, I'll post again soon once we have machined some of these parts.

Regards,

Dave@Nerv

[BOOTLEG]

Nerv,

That looks like "substance" to me. My S sits patiently waiting for a heart transplant so I will not turn the channel. I will continue to follow your progress.

Thanks for the update.

[B6T]

Originally Posted by Nerv

A new flywheel is being designed as well that will accept the 10 bolt crank pattern and actually place the timing ring in the proper orientation for the manual transmission pickup location.

That is it for now, I'll post again soon once we have machined some of these parts.

Regards,

Dave@Nerv

Did you consider the FWD 6-speed transmission from the B6 chassis A4?

Pros:
- Crank position sensor is in the correct location
- You can use an off the shelf flywheel and clutch
- Correct starter location for the V8
- 01A based like the Boxster transmission

Cons:
- Have to design shift mechanism since these are rod actuated and the mechanism is on the LH side. The kit car guys might have something in existence that works already though.
- Mounts - but you're designing those anyway.

Unknowns:
- Axles, but you might be able to find an VW/Audi axle that works.


I have actually purchased a 2.7tt to swap. I was looking for a base 2.7t 2000+ car since that Motronic version integrates better with the ME7 based 2.7t and V8 Audi stuff than does the older non-E-gas Boxsters. I ended up finding a nice 2003 Boxster S which I plan to keep H6 for the time being. So swap plans are on hold.

Until this point I've done a lot of thought about how I'd do the swap, but no actual measurement since I didn't have the Boxster to take measurements from. I also don't have a $80,000 laser scanner available, nor a machine shop, despite having used those scanners at work and having mechanical design and CNC programming experience. I wish I had your resources! Let me know if I can help out at all!