Twin Charged V6 Swap Build Page

[DarkStar]

Well guys, unfortunately there isn't too much to throw up. If you haven't been following the FB Build Page, You can hear crickets chirping. It hasn't been completely uneventful tho. I did start prototype designing stages in a 3D Environment as well as a few test cuts/welds. I am getting closer to a final design. In the mean time, I am working out a deal on a new shop with a partner of mine, and all new equipment. Should be happening very soon, so the final design will be done in a new, virgin clean shop! Anyway. Lets see what I got to share!

The current design is as follows. Tubular side arms and rear tie brace. The flat plates are made to pinch in between the Aluminum Tie Straps on the control Arms. They are currently made out of 3/16" Cold.


Plates were cut, As well as the front mount bar.



Pipes aren't done being bent yet. I had to send them off to a friends shop because my largest die is not large enough. So once I get them in. I'll fit them up, hopefully all goes well and I will be welding it up. Then I'll be able to toss the engine up in there so I can make the engine mount brackets next.

In other news, I wanted to get a little creative so I am designing a replacement crankcase ventilation plate. Here's what the original looks like, its very prone to clogging up.


Anyway, the idea is to make a completely new top cover to take advantage of the factory Porsche Boxster Oil Fill Tube! There is soo much spare room under the intake manifold. I'm not too deep in progression with that. I will be adding an -12 or -10an bung for the center crankcase vent which will meet up with the valve cover vents and be routed to a Perrin AOS. But as you can see, it will allow me to connect a tube to the Boxsters factory oil fill and then I will replace the oil fill valve cover with the one without the fill tube.


As for the engine, it is still stripped. All parts have been properly cleaned, lubed and covered while we wait for that thing called a job to start producing more money for me to funnel into this project! If I can acquire this deal for the new shop, I should get a nice increase in wages so plus plus! Thanks for reading up. I know its not much but I'm getting bored :'(

[DarkStar]

I have almost completely started from scratch. I was not liking the "Cheap" like method of building the engine cradle. At first it seemed ok, but things just bugged me about the way it looked.

So I been hard at work designing an almost completely 3D Designed Engine Swap Cradle. Its still in its early stages, but if things go right, I'll be able to manufacture with a pretty decent turn around time.


The inside is the same thickness as the stock Porsche mount so the original Studs or new ones can be used. Also fitted with Anti Crush Tubes inside.


And for some better, more uplifting news!




I'm taking in some measurements. This is only a test fit, Just so I don't run into anything. The engine and Transmission have to be lowered about 1-1.5" to fit properly, but going too low has axle rub issues as well as potential dangerous axle angle. Last thing I want is continuous axle failure with the added power. Right now in the photo the Transmission is just sitting on the 2 Suspension K Members which is about 1.5" drop. And eye balling it, its pretty level. My garage and the car for sure isn't level right now so I can't judge too much until I grab a digital level. BUT for now, It looks pretty dead in there.

I'm a lil undecided on what to do about engine mounts. I was thinking of fabbing it up so that it will accept OEM Audi mounts, that was the original idea. Or I could just make a whole new unit, engine block and cradle side separated by a nice urethane bushing.

We'll see how it goes!

[DarkStar]

Got scans of the Engine Box and the Engine/Transmission yesterday. My measurements are checking out! Once the scan of the engine is done being aligned and uploaded, I'll input it and place it where it belongs. I'm designing this to use Audi Mounts. So I can pickup a set of ECS or 034 Solids from a S4 and it will bolt right in.



Next I'll throw the pattern onto the CNC Plasma Table and cut out all the sheet metal patterns, fold them and weld them. I want to make a Jig afterward so it is easy to fab up more later on without needing to yank the engine out of my personal car.

Hope to have more for you guys, but money is tight right now so progress is slow.