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Old 10-14-2014, 05:20 AM   #1
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Rallycross Porsche Boxster

Heres my project at the moment.

a 2003 Boxster, being built for Rallycross in the UK. I dont know if Rallycross in the US is the same as we have in europe? I know your Autocross is actually what we call Autotest/Autosolo. Our Autocross is like Rallycross, but all on dirt (no tarmac sections), and up to 6 cars race at a time.









The girl is my friend, Hannah, she builds race cars, and also Hillclimbs a Toyota Paseo - which we built, I use it for rallycross at the moment.



Hannah has got some serious fibreglassing skills. She's also made panels for other rally cars, and one of the UK's top Rallycross guys


The Boxster was purchased from http://9apart.co.uk, which is a Porsche specialist here in the UK.
I bought it as a bare straight shell with no crash damage, and stripped everything left out of it.
As you can see the front end has been cut away and reinforced chassis legs with tube.
The engine bay has been cut away, and will be paneled out with aluminium sheet.


Oh, and the car will be running a 1.9 TDi motor and Transaxle from a Passat.



Check out our facebook page for more pics of the porsche, and also the toyota too

https://www.facebook.com/AngrySpiderRacing


Last edited by RobScott; 10-14-2014 at 07:19 AM.
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Old 10-14-2014, 07:07 AM   #2
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I'm listening...
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Old 10-14-2014, 07:36 AM   #3
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Very interesting! Why a VW 1.9 TDI? Not exactly a powerhouse motor. Is a certain level of power, in this case about 100, a Rallycross requirement for the class you run in? Keep us posted.

Hey, is that a Deloren?
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Old 10-14-2014, 07:43 AM   #4
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simple answer is porsche engines are expensive, and not too reliable.

There are guys in my class with 1.9 TDi Audi TT's, running around 250bhp and 400lb torque.

There are no limitations in the class, apart from it has to be 2wd (Super modified class)

Yeah thats a Delorean
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Old 10-14-2014, 08:06 AM   #5
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Originally Posted by RobScott View Post
simple answer is porsche engines are expensive, and not too reliable.

There are guys in my class with 1.9 TDi Audi TT's, running around 250bhp and 400lb torque.

There are no limitations in the class, apart from it has to be 2wd (Super modified class)
You are right about that and nothing wrong with 400 lb torque.
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Old 10-14-2014, 08:41 AM   #6
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Very cool! Liked the page on Facebook. Good luck, and I look forward to watching your progress!
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Old 10-14-2014, 09:31 AM   #7
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That looks great - will be following your progress with interest!
It is a shame rally cross is not bigger in the USA. It is great to watch. I miss Hill climbs - which do not really exist in the USA. There are some great twisty hill roads around soCal which would be really good for hill climbs. I guess it is the cost of insurance that makes it hard to run an event on public (closed) roads here.
Imagine something like this racing up Mulholland!
https://www.youtube.com/watch?v=9_8B0mkrc_8
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Old 10-15-2014, 11:21 PM   #8
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we dont run any closed road events over here, havent been able to for a long time.
Our hillclimbs and rallies are all on private land.
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Old 10-16-2014, 04:34 AM   #9
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i see a few of you guys are running fibreglass roofs,

We decided to keep the origional aluminuim roof, but cut out the inner skin.. its just a bit safter than a fibreglass item if i flip the car.
Cuting out the inner skin gets the roof real light, you can easily pick it up and fit to the car on your own.

Also, the fibreglass panels will be made from carbon kevlar, one of our sponsors is a Fibreglass company, so we can get the carbon kevlar at a seriously good price the fibreglass panels we have made for now are for mockup of the car
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Old 10-16-2014, 04:54 AM   #10
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Originally Posted by njbray View Post
That looks great - will be following your progress with interest!
It is a shame rally cross is not bigger in the USA. It is great to watch. I miss Hill climbs - which do not really exist in the USA. There are some great twisty hill roads around soCal which would be really good for hill climbs. I guess it is the cost of insurance that makes it hard to run an event on public (closed) roads here.
Imagine something like this racing up Mulholland!
https://www.youtube.com/watch?v=9_8B0mkrc_8
There's a pretty healthy closed-public-road hillclimb scene on the east coast. There are not a whole lot of events, but we have a couple of consistently recurring ones.
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Old 10-16-2014, 07:55 AM   #11
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You are right about that and nothing wrong with 400 lb torque.
Other than trying to hook it up in the dirt.
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Old 10-16-2014, 08:01 AM   #12
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Originally Posted by RobScott View Post
i see a few of you guys are running fibreglass roofs,

We decided to keep the origional aluminuim roof, but cut out the inner skin.. its just a bit safter than a fibreglass item if i flip the car.
Cuting out the inner skin gets the roof real light, you can easily pick it up and fit to the car on your own.
55 pounds fully intact.



Also, the fibreglass panels will be made from carbon kevlar, one of our sponsors is a Fibreglass company, so we can get the carbon kevlar at a seriously good price the fibreglass panels we have made for now are for mockup of the car
I would like to see Hannah take a crack at making all the body panels in Carbon Kevlar!
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Old 10-16-2014, 05:06 PM   #13
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You have a great sport, an exciting Boxster project and an enviable girlfriend. Life is good, eh?
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Old 10-16-2014, 11:15 PM   #14
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lol, she aint my girlfriend, she is a friend of mine from the local race car club, she is better at building cars than 99% of the guys in the club! lol
I'm married, and have a very understanding wife, my garage is about 15 miles from my house, I work all day, then go to the garage till late working on the cars.

Yeah Hannah is quite a pro at fibreglassing, she can make body panels that are thin, but take some serious abuse.
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Old 10-17-2014, 05:10 AM   #15
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lol, she aint my girlfriend, she is a friend of mine from the local race car club, she is better at building cars than 99% of the guys in the club! lol
I'm married, and have a very understanding wife, my garage is about 15 miles from my house, I work all day, then go to the garage till late working on the cars.

Yeah Hannah is quite a pro at fibreglassing, she can make body panels that are thin, but take some serious abuse.
Wow go Hannah go!
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Old 11-01-2014, 10:02 AM   #16
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Roll cage looking good and rear arches widened for wider wheels and more suspension travel. Once the arches have been completed, we will take molds of them and cast fibreglass items. The metal arches will then be cut off and binned. A lot of work, but worth it. While the arches were off, we also cut some inner skins out This has got to be the lightest boxster ever












Last edited by RobScott; 11-01-2014 at 10:11 AM.
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Old 11-26-2014, 01:03 PM   #17
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Carbon Kevlar rear wings :-)






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Old 11-27-2014, 07:48 PM   #18
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Nice work...are producing a rear deck lid in carbon Kevlar? Perhaps one that could be a direct replacement for a stock one? Maybe a clam shell too?
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Old 11-27-2014, 10:50 PM   #19
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yep yep, Hannah made a rear boot lid in carbon Kevlar, its only single skinned though, as it will be dzus clipped to the car.
we can produce them to sell, but only in single skin form, we have too many molds laying around as it is,

We will be making the clam shell, and doors in carbon Kevlar (also that one piece front end too)
the rear wings, although they are wider, can be trimmed down to suite standard width cars too. If you notice I have also cut more out of the arch, for more wheel travel... i'll be doing the same to the front too.

We have had a change in thought about the engine too. looks like we will be going for a 2.7 bi-turbo Audi V6

Last edited by RobScott; 11-27-2014 at 10:56 PM.
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Old 11-28-2014, 06:28 AM   #20
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Like the amazing work with fiber glass and Kevlar!

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