Any progress on V8 engine swap options?

[B6T]

I was just in the garage measuring the 4.2L yesterday to see how it would fit in the engine bay of the Boxster. I got a little scared. So it's nice to see these pics Dave!

I'm curious though, in what way to do you plan on cutting up the engine cover?

Also, Tom, on the subject of the 2.7t swap. The way I looked at it was if you have to fabricate the turbo manifolds/up-pipes, exhaust, and everything else that makes the 2.7t different from a normal 2.8L V6... then why wouldn't you just swap in the engine with 2 extra cylinders to begin with. A turbo V8 Boxster is way cooler than a turbo V6 Boxster... just saying

[titaniumdave]

Originally Posted by B6T

I'm curious though, in what way to do you plan on cutting up the engine cover?

Also, Tom, on the subject of the 2.7t swap. The way I looked at it was if you have to fabricate the turbo manifolds/up-pipes, exhaust, and everything else that makes the 2.7t different from a normal 2.8L V6... then why wouldn't you just swap in the engine with 2 extra cylinders to begin with. A turbo V8 Boxster is way cooler than a turbo V6 Boxster... just saying

2 thoughts here, the final cradle for this style of installation will be another 25mm lower on the front. I realize with the steel cross suspension support in place, the oil pan is well above the line the cross member defines. This will help get more front head/belt cover clearance. I think this will fit with just some hammer massaging of the front engine cover areas. It will also help move the TB away from the cover in the back where the middle tab will need to be cut off. I am looking at the intake to see if I can machine the TB flange at an angle, tipping the TB down and moving it forward at the same time. This works fine for my race car since the EGR system will be deleted/re-routed into a catch can. Not sure how this will work out with a street car but there appears to be plenty of points where the EGR system can pull vacuum to make the ECU happy.

As far as the V6 goes, my buddy who is helping likes turbo set ups because they can make lots of torque. We both come from the NSX world where everything is V6 since you can't stuff more cylinders in the NSX engine hole with out putting the motor longitudinal rather than transverse.

Once this car is running, I will start on a new cradle that will work for the V6 and maybe LS V8 options for those who really want to break transmissions...it will have this style cradle replacing the rear steel suspension brace:
https://www.engineswapdepot.com/?p=11960

[Escy]

Originally Posted by B6T

Also, Tom, on the subject of the 2.7t swap. The way I looked at it was if you have to fabricate the turbo manifolds/up-pipes, exhaust, and everything else that makes the 2.7t different from a normal 2.8L V6... then why wouldn't you just swap in the engine with 2 extra cylinders to begin with. A turbo V8 Boxster is way cooler than a turbo V6 Boxster... just saying

Yeah, that thought crossed my mind. The way I approached my first 2.7t build, I could have put a turbo V8 in there. I don't think a naturally aspirated V8 with a turbo kit would do the numbers I wanted out of the V6 (was looking for 600bhp) without the bottom end being built and the RS6 V8's are expensive.

The other thing that puts me off the V8 is they always seem to end up being a bit of hack job when it comes to the intake and throttle body. Fabricating an inlet manifold seems to be the only tidy way around it.

I'm building another 2.7t and plan on keeping the turbos in the standard location this time.

[Escy]

The turbos won't be able to be kept in the stock location without doing some cutting of the bodyshell. I'm not sure how much yet.

My old 2.7t had forged rods in it.

What's the distance between the the diff output flange and the bellhousing on your 01a gearbox? This is important, you might find you'll be needing that spacer the S4 uses.

[B6T]

Around ~138mm between the bellhousing flange and the axis of rotation on the diff output flange.


EDIT:
This is what happens when I do math late at night. Measurement should be about:

Driveshaft Flange Diameter (108mm/2)
+Distance from flange to bellhousing surface 138mm
= 192mm

[Escy]

I don't know if i'm measuring something different to you. Is the middle of the diff output flange the same distance to the bellhousing as on the Boxster 5 speed? If it's shorter that gearbox probably won't be suitable, if it's further it'll be fine. I'm offering up a 2.7t at the moment with the gearbox spacer and a boxster 5 speed, it's tight on driveshaft clearance.

[B6T]

What I have should be the identical transmission as a 5-speed Boxster... so it should work...

I'll look for an ID tag next time I'm in the garage.

[specboxCO]

I used this flywheel:

Audi V8 4.2 8 Bolt to O1E/O1A Gearbox | TTV Racing Component Manufacturers

with an Audi S4 B5 clutch friction & Pressure plate. Works on a 986 5 speed and 987 5 & 6 speed boxes.

I had to drill the transmission for the manual crank position sensor and use spacers to get it the correct depth in the bellhousing.

Everything bolted up easily in the end and works great. I like that i'm not using Porsche clutch consumables - much easier on the wallet.

[titaniumdave]

Originally Posted by specboxCO

I used this flywheel:

Audi V8 4.2 8 Bolt to O1E/O1A Gearbox | TTV Racing Component Manufacturers

with an Audi S4 B5 clutch friction & Pressure plate. Works on a 986 5 speed and 987 5 & 6 speed boxes.

I had to drill the transmission for the manual crank position sensor and use spacers to get it the correct depth in the bellhousing.

Everything bolted up easily in the end and works great. I like that i'm not using Porsche clutch consumables - much easier on the wallet.

Thanks, hope to have my bits all trail fit today with the clutch parts.

[titaniumdave]

Cradle came back from powdercoat...dog would not get out of the picture.

[titaniumdave]

Update:
We used this clutch kit because it's cheap and seems 'good enough':
https://www.europaparts.com/clutch-conversion-kit-52405618-valeo.html
All bits fit and the only thing needed is a 3mm spacer behind the flywheel to get the starter ring to clear when the drive gear is retracted. This will leave 7mm of flywheel bolt thread engaged in the crank with the included 30mm flywheel bolts and I want at least 12mm. I will either recess the flywheel 5mm or get longer bolt. I like the idea of recessing the bolt holes because the steel flywheel is very heavy and I plan on machining 8mm off the thickness of the entire flywheel to remove weight. There is plenty of travel on the throw out bearing, will actually be closer to the stock Boxster throw if the stack was reduced by 8mm. I'm guessing this will drop 4 lb. and still allow use of the OEM style clutch disc and pressure plate for rebuilds so cheap running cost once we are done. Keeping the motor NA should mean the clutch should be plenty robust for a lightened race car build...fingers crossed.

We are using the 11mm transmission/motor spacer, part # 01E 103 551C

[titaniumdave]

I put the dog outside

[titaniumdave]

I need a 3mm flywheel/crank spacer, anyone know where to get one? I can make some but would rather buy one...

[78F350]

Originally Posted by titaniumdave

I need a 3mm flywheel/crank spacer, anyone know where to get one? I can make some but would rather buy one...

I got my bell housing spacer from wolf auto parts. Give them a call, they have lots of used Audi stuff.
Not sure what size this one is: https://www.wolfautoparts.com/2000-2001-2002-audi-s4-b5-flexplate-shim-w-bolt-set-175459.html

[specboxCO]

This thread has gone a bit quiet lately, so I thought I would post something motivational.

I have completed my V8 swap and got it to the track for its first test.

https://youtu.be/7ecn5ByaAtM

Might not look like much, but its been 2 years in the building. Runs a 40v 2002 Audi 4.2 using an Audi ecu, Cayman 5 speed transmission (may swap to a 6 speed now I have the VSS problem sorted) volvo electric power steering, BMW ABS system.

Will be racing it in 2 weeks at High Plains Raceway in Denver in the World Racing League endurance series.

[dlud]

It sounds great! I'm considering picking up another 986 and doing an Audi 2.7t swap. I would be interested in your thoughts on the v-8 vs the v-6 choice.

[specboxCO]

I think the 2.7t is a much better idea for a daily driver or occasional track car. Can make way more power than the V8 and is probably an easier install.

I wanted the V8, as I was building an endurance racing car and wanted an NA. Turbos seem to cause a lot of issue there, difficult to get the heat out of the car. Plus it sounds great!

[itsnotanova]

Originally Posted by specboxCO

This thread has gone a bit quiet lately, so I thought I would post something motivational.

I have completed my V8 swap and got it to the track for its first test.

https://youtu.be/7ecn5ByaAtM

Might not look like much, but its been 2 years in the building. Runs a 40v 2002 Audi 4.2 using an Audi ecu, Cayman 5 speed transmission (may swap to a 6 speed now I have the VSS problem sorted) volvo electric power steering, BMW ABS system.

Will be racing it in 2 weeks at High Plains Raceway in Denver in the World Racing League endurance series.

The video is too short

[B6T]

Originally Posted by specboxCO

This thread has gone a bit quiet lately, so I thought I would post something motivational.

I have completed my V8 swap and got it to the track for its first test.

https://youtu.be/7ecn5ByaAtM

Might not look like much, but its been 2 years in the building. Runs a 40v 2002 Audi 4.2 using an Audi ecu, Cayman 5 speed transmission (may swap to a 6 speed now I have the VSS problem sorted) volvo electric power steering, BMW ABS system.

Will be racing it in 2 weeks at High Plains Raceway in Denver in the World Racing League endurance series.

Did changing that value in the ECU program solve the VSS issue? Did you eliminate the cluster from the trunk?

[specboxCO]

Originally Posted by B6T

Did changing that value in the ECU program solve the VSS issue? Did you eliminate the cluster from the trunk?

Yes. Managed to up the rev limit in the ECU for the No VSS issue. Runs perfectly now.