Wow super similar widebody design that he’s working on right now. That’s a dream build. Definitely working with a different budget...

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Progress continues, I'll post later on the hardware progress. In the meantime I've tackled the gauge problem. The stand alone computer won't be able to talk to the Porsche gauges so I made a digital dash using realdash and an iPad that sits behind the factory cluster. Checkout the youtube link below of it in action

Video of the gauge in action
https://youtu.be/xPJ0kvIynyk

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Wow, that's awesome!

This is such an awesome build, do you ever bring it to c&c?

Thanks! Pre-covid I was normally there with my 911 but I plan on bringing the Boxster this summer (maybe on a trailer, I’ll be that guy). Let me know when you’re going on all I’ll meet you there if I’m not on baby duty (or if I am on baby duty and have finally have replaced my non-baby friendly straight pipes on the 911).

More turbo goodies are arriving, all the fuel system parts are in but I'm still waiting on the Turbos to arrive (next week hopefully) and the final intercooler is backordered so who knows. Last night I got the coolant system roughed in and cut some more of the body panels that hide underneath the aluminum widebody (this also makes room for the intercoolers that will sit just in front of the rear wheels). I have cut out a tremendous amount of steel so far, I'm hoping with the V8 and the twin turbo system (which is probably 130lbs) I'll still be under 2500lbs. At a minimum the weight balance is going to off. This weekend I'll throw the fuel system in, button up the coolant system and build at least one new wheel well to accommodate the 8" wider body and new 12" wide rear wheels, I'm going to cut out all the steel from the wheel wells, it'll all be aluminum. I have a feeling I'm going to end up with just the frame rails and a tubular steel rear frame here soon. more to come later:cheers:

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Definitely a FrankenBoxster
Very cool!!!!! :cheers:

Damn, just catching up on this, epic build!

Don't see many details re the engine swap. Which Audi V8 did you go with? What turbos? What management? I imagine you are also upgrading internals on the engine before going forced induction?

Engine: I’ve changed up the engine three times, sent one engine back and still have another sitting around but settled on an Audi ABZ 4.2l V8 which if I hadn’t already changed my mind so many times I would have moved onto a different platform. The ABZ bolts up to the Boxster trans which is nice but the real benefit is that it’s an incredibly short motor (same length as the Boxster flat 6 so it actually allows the trans to sit in the factory location. With the trans in the factory location you don’t have weird drive axle angles which is a big problem on a track car. The problem with the motor (I now know) is that forged internals are all NLA so for now it’ll be stock. People run stock internals up to 1,000hp so I don’t think my goal of half that will be a problem...we’ll see.

Engine management: I’ve also changed this up three times too starting with a reflashed stock Audi ecu, then mega squirt which I just sent back, now I’m waiting on a VEMs ecu which is being baseline tuned for my setup and they’re making a harness for me (totally plug and play besides three wires to connect to the boxster..how cool is that!). The companies called EFI Express, awesome guys!

Turbo’s: I just received the turbos this weekend. I ordered the smallest S200SX-E turbos they sold from Borg Warner but they shipped me the largest S200SX-Es so I’m not sure if I’ll return them or change my approach a bit. I’m targeting 520hp for now at 8psi. If I can find internals (or have them made) the turbo, fuel and cooling setup will take the engine to 800hp. I hope Im never stupid enough to try that.

you are gonna run the stock 5 speed with 520hp?

How many do you plan to replace per event?

I'm hoping easy shifting and no launches and a cooler will get me through an event or so, I'm sourcing an S transmission to replace it.

I have a feeling this whole thing is going to look like the BluesMobile in the final scene. But hey...we’ll see. At a minimum you all will get a good laugh when everything explodes.

Turbos are bolted on! They just fit below the trunk lid, next I'll need to get the charge pipes fab'ed up, the waste gates installed and then wiring and oil plumbing. Soooo much work to do, I feel like I've gone off the deep end with this project:cheers:

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Oops looks like I posted the same photo twice, here's the correct one

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It's all awesome! I think it may be about time to change your signature:

I was talking with one of the GRM guys in person (pretty sure that it was 'Stafford1500') about boost with the Audi 4.2s. He mentioned changing the head gasket to adjust the compression. I don't remember the details, but I think that he recommended a thicker gasket to slightly reduce the compression. If you are boosting a stock 4.2 now, you may want to look into that for when you build up the replacement engine.

There may be a few guys on the AudiWorld Forums that have the forged internals tucked away. "audinutt" offered me a set about three years ago, but at the time I didn't plan to tear down an engine. It may be worth asking. If they see your build they will probably be happy to help out.

This is one of the reasons I went to e85, e85 has almost 3 times the evaporative cooling and reduces the detonation for high compression motors so there's no need to reduce compression. I also had EFI Express put the whole plan together, they have a tremendous amount of knowledge turo'ing these motors so I basically just returned everything I bought and bought their recommended setup.

Thanks for letting me know about the forged internals tucked away! I'm reaching out to them right now and will report back.

I'm super concerned about heat on this car so I've gone a bit overboard on a few things including these intercoolers. I've instructed a lot of students that had turbo cars, and almost all of them (including the factory turbo'ed cars) haven't survived a track weekend so I'm trying to be very careful. The intercooler setup I've designed should be good for over 2,000hp, it uses a huge water to air intercooler that is cooled by two large radiators that are squeezed into the rear fenders. I still need to fab up some aluminum plates to seal the doors up but its taking shape. :cheers:

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Any concern with the rearward swept angle of the rads creating lift as the air goes down through them, or does the wheel well turbulence negate it?

So I’ll have to admit I really have no idea... look worst case I’ll add some angle of attack to the rear wing. The Front fenders stick out further than rears so it won’t be getting a ton of airflow. Good point though.

That isn't an issue. The air exiting at an angle doesn't generate lift or downforce.

Was this car a base or S originally? The S came with bigger coolant tubes from the back to the front.

It was a base 2.5, I thought about replacing the lines but I think I'm better just making custom lines that don't split since I'm not using the side radiators anymore. I'm hoping that the larger front radiator, large oil cooler and the evaporative cooling I'm getting from running e85 will make up for the small coolant lines. It helps that its almost never under 100mph so it'll have plenty of airflow.

Hardly worth a post but I got the intercooler test fitted and it looks..a bit small.

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This weekend I was able to make a little progress, I got the intercooler and piping roughed in and finally received my modified engine harness, flex fuel kit and the VEMs standalone which has been preloaded with two tunes (E85 and gas) for my turbos, engine, etc. The harness is now totally plug and play, no wiring required! Definitely the easy button. I have to show off these injectors too, probably the most expensive part of the build but designed for both tunes and tested for both tunes. Its the little things like this that have really added up. :cheers:

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I feel like this is starting to get pretty ridiculous looking, but its getting closer...:cheers:

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If you mean ridiculously cool then yeah I'll second that!

The exhaust pipes are great! Are you planning to blow the wing?

Yep exactly! The exhaust will be angle up to speed the air under under the wing and the pipes will be shortened to hopefully prevent the wing from catching fire.

Another small update. With the help of a buddy of mine we started actually welding stuff together. This “exhaust” plan is crazy, I hope I don’t regret it.

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I'm sure I'm going way overboard on these micro exhaust updates but it has been such a pain to get these at the same angle (since the turbos sit at different angles) I thought I would at least add a post to make myself feel a little better. They're now aimed just below the wing, I've also sold my wing so I can replace it with an aluminum (fire resistant one)

:cheers:

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That's beautiful man, who put together the VEMS for you?

Sent from my POCOPHONE F1 using Tapatalk

EFI Express built the VEMs and supplied a ton of the parts. Absolutely awesome guys to work with. They knew exactly what I needed, steered me onto a much better path and bench tuned the VEMs for a e85 and for a flex fuel setup. They even modified my harness so this whole thing is plug and play. Can’t say enough good things about them.

Its been awhile since my last post so I thought I'd give a quick update, I've made a lot of progress on a lot of small things but I still have a long way to go. The oil system is just about done with the exception of the oil cooler which is roughed in, you can see the two AN fittings pointing towards the back of the car that will supply and return the oil from the missing cooler. Most of the piping is back at the fab shop getting some adjustments made so the charge pipes, exhaust, waste gates and blow off valve are all in a holding pattern.

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Very nice progress! She's coming together beautifully.

What are the two air filters behind the passenger rear axle?

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I’m actually using one of the two tanks there, it receives the oil after its pumped through the turbos. After passing through the turbos the oil is aerated so it settles in that tank before being pumped back into the engine via a scavenger pump. There’s two tanks because I got it off eBay(old NASCAR part) and it came with two welded together. I’ve bought a lot of eBay nascar parts, they’re well made and cheap. Not always great looking though. I have a similar tank on the engine that replaced the air oil separator.

That's really interesting, I had never thought to look for used nascar equipment.

What's the purpose of the aeration? Faster cooling?

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The aeration isn’t by design, it’s due to oil basing through the fast moving turbos. It’s a bad thing

Oh got it, I read your post incorrectly. I didn't think aeration was a good thing but I didn't want to question lol. Keep us posted!

Btw, did you find a wire to use for your turbo oil pump? Or are you gonna use an aftermarket timer.

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I took a break from engine work and started on the trunk. I had to ditch the lexan trunk since it probably would have melted so I'm back to the old steel trunk. I was able to pull about a third of the weight off of it by skinning it and cut the first of two holes for the turbos. There will be a hole like this on each side. I think its going to look pretty good once cleaned up and wrapped:cheers:

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I worked on the trunk a little more this morning, I'll admit the photos don't look great put in person the turbos are centered under the trunk holes. It'll look much better wrapped too. Next up I need to install the mesh covers over the turbos and make the aluminum sides to the oil cooler vent

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Question: Are you going to put a little scoop or something over the turbo holes to try and direct some cool air towards the intakes? It might not be much, but I can see them sucking in some warm air. Might not be a big deal, but it might be something to think about.

Also, that exhaust setup is going to look and sound MEAN.

Random thought; is yours still registered for road use? This will be the most fun errand runner ever.