Spec Boxster Build

[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?

[steved0x]

Are you going to trim your rearmost underbody plastic panel to fit or just leave it off? Mine is off for now, it was so busted up.already it was barely doing anything anyway...

[JayG]

Originally Posted by 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?

well it is a LN part ya know

[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.

[thstone]

Today, I started work on weight reduction. Pulled the front bumper cover and both front inner fender liners.

First, I removed the windshield wiper fluid reservoir and filler neck. The reservoir is inside the rear portion of the driver's side fender and the filler neck god thru the fender to front trunk where the spout is located.

Next, I removed the single remaining radiator fan (passenger side). This was a 5 min job with the front bumper cover and inner fender liner already removed.

Total weight removed: 8.5 lbs. That's 20% of my 40lb goal!

Passenger side radiator - impact "damage" to the radiator from track debris is obvious - need to install some screening behind the bumper cover grills to prevent more damage;


Backside of passenger side radiator with fan removed;


Windshield wiper fluid reservoir, fill neck, radiator fan, and a little bit of wiring removed;

[JayG]

Maybe Nutrisystem for the remaining 32 lbs?

Happy New Year Tom

[steved0x]

I tried to take my wiper fluid reservoir out once and could never get it out (I was trying to route a new hood cable). Now my fluid won't spray, I think something got loosened (pump maybe?) and I need to get under there and fix it. Besides the one bolt, did you recall doing anything special or tricky to remove it?

Thanks

Steve

[thstone]

Originally Posted by JayG

Maybe Nutrisystem for the remaining 32 lbs?

Happy New Year Tom

Its so much easier to just unbolt the weight from the car! Wish it was that easy with me!

[thstone]

Originally Posted by steved0x

I tried to take my wiper fluid reservoir out once and could never get it out (I was trying to route a new hood cable). Now my fluid won't spray, I think something got loosened (pump maybe?) and I need to get under there and fix it. Besides the one bolt, did you recall doing anything special or tricky to remove it?

There is just the one bolt. The rear of the reservoir is held in by two rubber plugs that fit into a bracket. Once the bolt is removed, just pull/yank the reservoir directly out from the bottom and the rubber plugs will pull out of the bracket. You have to give it a good hard pull and if you didn't know that it was just a rubber plug was holding it in, you'd be convinced that you'd break something - but you won't.

I'll post a picture tomorrow.

[steved0x]

Originally Posted by thstone

There is just

the one bolt. The rear of the reservoir is held in by two rubber plugs that fit into a bracket. Once the bolt is removed, just pull/yank the reservoir directly out from the bottom and the rubber plugs will pull out of the bracket. You have to give it a good hard pull and if you didn't know that it was just a rubber plug was holding it in, you'd be convinced that you'd break something - but you won't.

I'll post a picture tomorrow.

I got under there this afternoon. Dang I had forgotten how big and long the driver side fender liner is... Dang...

Once it was off I.looked under there and the hose was off. I reconnected it and all was good. I could see the rubber plugs but was lucky and didn't have to take it off.

Thank.you.

Steve

[thstone]

A little more weight reduction today - cleaned up the wiring and tubes in the front trunk and inside the fenders. No need for radiator fan wires, side marker lights, etc.

Weight removed = 1.5lb; that brings the total to 10lbs or 25% of the 40lb goal.

[thstone]

Originally Posted by JayG

Maybe Nutrisystem for the remaining 32 lbs?

Happy New Year Tom

Haha! But in reality, you're right. I should probably seriously consider losing 10-20lbs myself.

[JayG]

Originally Posted by thstone

Haha! But in reality, you're right. I should probably seriously consider losing 10-20lbs myself.

you're not the only one

[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]

A late Christmas present to myself arrived today!

Sparco Ergo halo seat. 18.3 lbs with no mounting hardware. Found it on sale for $695 (reg $995).

[Gary R.]

Like the Sparco seats, my Pro ADV fit me well in my last car. Nice find!

[steved0x]

Sweet! And if you can re-use your other mounting hardware from the previous sparco seat, double sweet!

[thstone]

Originally Posted by Gary R.

Like the Sparco seats, my Pro ADV fit me well in my last car. Nice find!

I seriously considered the Pro ADV but it didn't come in a larger size. Its a great seat.