Spec Boxster Build

[RedTele58]

Tom - I want to give you a shout-out for this discussion on oiling and the different sump options.

After you started this discussion before Thanksgiving, I decided I needed to do something with regards to keeping my Orange/Black 269 DE car safer from oil starvation. While I'm not driving at your level and pulling the lateral G's that you are, I'm still driving the car a lot harder then when I began. After this discussion, I decided it was better to be safe than sorry.

I had the 269 car at my mechanic a few weeks ago for some different things, and after discussion, we decided while he had the car, to have him install the LN Engineering 2 QT deep sump and the X-51 style windage tray. We also went with a spin-on filter.

It'll be mid-March before I'll be back on the track, but I'll be feeling a bit more comfortable. Thanks for all your continued help and advice - both on and off the board!

Rick

[thstone]

Thanks for all of the input! (and thanks for the shout-out Rick)

The tray above with the big holes was for reference as it got me thinking about the oil returns. The TechnoSump kit has the 996/997 swirl returns that do not have the big cans on the ends. Since I plan to use the 996/997 returns that came with the kit, I am not planning on cutting any holes in the horizontal baffle (as there aren't any holes in the TechnoSump/TunesRS kit or the LN Engineering kit).

Here is where I am today - this looks exactly like the LN/Bilt Racing kit (Bilt Racing 2QT Deep Sump Oil Pan Kit inc. Pickup-Tube Extension, Windage Tray & X51 Baffle LN Engineering)

Please excuse my lack of fine metal working skills on the windage tray - I'm just a DIY hack. Installation tomorrow...

[steved0x]

Originally Posted by thstone

Please excuse my lack of fine metal working skills on the windage tray - I'm just a DIY hack. Installation tomorrow...

Looks pretty good to me, as good as the factory LN piece!

[steved0x]

The LN kit has the orange rubber pieces removed from the bottom parts of the x-51 baffle, are you planning to keep them on yours (or are you preserving the baffle during the test fitting for a future sale since you have 2?) I would be afraid they would fall off and block the oil flow. The rest of them are bound very tightly by pressure when it is installed but I would worry about those bottom 2. I'm not sure how tightly they are glued on but when I got that baffle new one of them had mostly fallen off and I had to reposition it.

[thstone]

Originally Posted by steved0x

The LN kit has the orange rubber pieces removed from the bottom parts of the x-51 baffle, are you planning to keep them on yours (or are you preserving the baffle during the test fitting for a future sale since you have 2?) I would be afraid they would fall off and block the oil flow. The rest of them are bound very tightly by pressure when it is installed but I would worry about those bottom 2. I'm not sure how tightly they are glued on but when I got that baffle new one of them had mostly fallen off and I had to reposition it.

Good eye! The photo was a quick test fit and I was planning on removing the two bottom rubber pieces prior to installation. I agree that it seems that they might come off.

[thstone]

I got the deep sump installed today. The filter and sump were perfectly clean but I found some old sealant stuck in the oil pickup screen. Its dark brown and flexible. This wasn't there about a year ago when I installed the EBS baffle. I know its not sealant from a year ago because I used the grey stuff and it was still grey where it had slightly seeped into the inside of the sump.

I will let the sealant cure overnight and will put oil in it tomorrow.

Here is the complete assy ready for installation;


Swapped the big can swirl pots for the 997 type that came with the kit;



Here is the old sealant that was in the oil pickup;

[jaykay]

Originally Posted by thstone

I got the deep sump installed today. The filter and sump were perfectly clean but I found some old sealant stuck in the oil pickup screen. Its dark brown and flexible. This wasn't there about a year ago when I installed the EBS baffle. I know its not sealant from a year ago because I used the grey stuff and it was still grey where it had slightly seeped into the inside of the sump.

I will let the sealant cure overnight and will put oil in it tomorrow.

Here is the complete assy ready for installation;


Swapped the big can swirl pots for the 997 type that came with the kit;



Here is the old sealant that was in the oil pickup;

Nice shot....where the oil return outlet "nozzles" aimed? Do they discharge inside the baffle or outside on top of the tray (h-baffle)?

[thstone]

Originally Posted by jaykay

Nice shot....where the oil return outlet "nozzles" aimed? Do they discharge inside the baffle or outside on top of the tray (h-baffle)?

This is the general location of the X-51/EBS baffle (excuse my poor graphic skills,but you get the general idea).

As you can see, the oil returns (both the Boxster stock returns and the 997 returns) discharge "outside" of the vertical baffle. With the horizontal windage tray installed, the oil discharges on top of the tray. Thus, return oil has to flow back thru the doors of the baffle to refill the sump.

[jaykay]

Originally Posted by thstone

This is the general location of the X-51/EBS baffle (excuse my poor graphic skills,but you get the general idea).

As you can see, the oil returns (both the Boxster stock returns and the 997 returns) discharge "outside" of the vertical baffle. With the horizontal windage tray installed, the oil discharges on top of the tray. Thus, return oil has to flow back thru the doors of the baffle to refill the sump.

Your graphic is good. This was what I was thinking I could see. Soooo when I did this I made sure that I had the old style swirl pots with big holes for them to protrude through where by the discharge was under the tray in the trapped volume with the pickup. This is a long time ago....I believe I thought this to be the best arrangment at the time. Return oil is feed directly into the trapped vol where the pick up sits.

I fail to see how the 997 returns are better returning oil on top??? Perhaps it's a deairation thing??

[thstone]

I replace brakes (pads & rotors) often enough that I received a free t-shirt along with a hand-written note from the manager of my rotor supplier today!

They do make very good and affordable rotors! I have probably gone through 15 sets of rotors without any problems over the past 5 years.

For example, OEM replacement rotors for early Boxster's are $48 rear and $53 front (ea). That's a full set for $202 with free shipping. Check them out at: Performance Brake Rotors | Brake Pads & More | Cquence.net

[Burg Boxster]

Excellent lead - which series & design are you running for Spec (dimpled & slotted or just slotted)? I need to replace mine for DEs this spring and their pricing looks outstanding - can do both axles for less than OE price for one!

Thanks!

[thstone]

Originally Posted by Burg Boxster

Excellent lead - which series & design are you running for Spec (dimpled & slotted or just slotted)? I need to replace mine for DEs this spring and their pricing looks outstanding - can do both axles for less than OE price for one!

Thanks!

I generally use the drilled set, but the dimpled/slotted are my second choice. I think that the drilled rotors have a better feel but that is probably just in my head.

[Gary R.]

Originally Posted by thstone

I replace brakes (pads & rotors) often enough that I received a free t-shirt along with a hand-written note from the manager of my rotor supplier today!

They do make very good and affordable rotors! I have probably gone through 15 sets of rotors without any problems over the past 5 years.

That's 3 sets of rotors per year, is this on one car?

[thstone]

Originally Posted by Gary R.

That's 3 sets of rotors per year, is this on one car?

The Boxster usually gets two sets per year plus one of the five family cars once every 2-3 years.

This year my son has also been driving the Boxster so its getting double the wear almost every weekend so I will probably do 4 brake changes this year on that car alone.

On average, I get about 10 track days out of a set of brakes.

[JayG]

I put Meyle drilled rotors on my 04 S
they were $82 for the front pair and $75 for the rear pair on ebay

[thstone]

Originally Posted by JayG

I put Meyle drilled rotors on my 04 S
they were $82 for the front pair and $75 for the rear pair on ebay

That is really good pricing for a known brand! Good find.

[thstone]

Here are pic's of the TechnoSump installed.

As you can see, the sump doesn't protrude lower than anything else and is roughly even with the rest of the underside of the car. I am not too worried about driving on the street, but I could imagine the front side of the sump acting like a plow and picking up a lot of dirt/grass/gravel during an off course excursion.

Replaced the brakes and trans fluid yesterday and will do the plugs today. Might as well get it all done as long as the car is up on the lift.

Sump install;


Nothing sticks out below the level of the bottom of the car;


But its not very far recessed either!

[JayG]

Time for a skid plate??

[ianacole]

Originally Posted by JayG

Time for a skid plate??

There is this: Bilt Racing MY97-08 Boxster/Cayman 2 Quart Deep Sump Stainless Steel Guard Plate LN Engineering

[thstone]

Thanks Jay and Ian - Yes, I am thinking about adding a skid plate or something similar to the Bilt Racing guard. My only problem with the Bilt Racing guard is that it seems way overpriced for a slightly bent piece of stock metal plate.

But then, what Porsche racing part isn't way overpriced?