BoxsterLS376 introduction - LS3 conversion :)

[BoxsterLS376]

Originally Posted by JRL

Hey John why can't you use the Boxster accelerator pedal assembly - it is drive by wire isn't it? Seem like the wires would be the same or at least similar enough. What am I missing?

Hey Randy,

Yes the porsche pedal is drive by wire, well the pedal itself is actually mechanical but it connects to an electric motor mounted in the dash. It is also a 6 wire setup like the GM unit, but i believe that the problem is in the voltages that GM uses vs. what Porsche uses, they no sprecken well~ Probably need a series of resistors or something - i'm sure you could make it work but when it comes to the throttle i'd like to keep it as simple as possible to avoid any potential issues.
J

[JRL]

Gottcha. Just seem simpler to use as much as possible but if no work then it no work.

I want to drop in and see the beast - when is a good time this week?

[BoxsterLS376]

Originally Posted by JRL

Gottcha. Just seem simpler to use as much as possible but if no work then it no work.

I want to drop in and see the beast - when is a good time this week?

Any day either mid morning 10ish~ or after 3pm would be best.
Thanks!
J

[Lcrivers816]

To whom it may concern,

The first Boxsters had full cable throttle bodies, I decided to go with a cable actuated throttle body for more throttle body options. I picked up an early Boxster floor pedal off of eBay for less than 100 bucks.

[JEhunter]

JJ - I sent you a PM

[BoxsterLS376]

Originally Posted by JEhunter

JJ - I sent you a PM

Got your PM - Sorry been a hectic week but will call you next week~


Uploading a new video now which will be available here in a few hours - http://youtu.be/8iZO-lNw5Hc

I was hoping to have the parts for my intake in by now but unfortunately took longer then expected due to the custom size - guess 3.5" 120* mandrel bends in stainless steel aren't that common :/ Anyway that along with my 4" intake piping and couplers should all be here Monday.

Been keeping on moving with little things and continued on with more wiring. Got the cable for the throttle pedal extended as well as the gas pedal mounted! The wiring is somewhat non standard as the pedal cable is not only wrapped like the rest of the harness but also has an additional layer of EMI/RFI tin/copper sleeving over it so which I found at a place called wirecare.com. Ordered 10 feet of it which cost about $27 with shipping which is a lot cheaper then some places were offering it.

The throttle pedal itself could probably be done a thousand ways, but in lieu of spending waaay to much time creating a masterpiece that no one will ever see except you all I tried the KISS method. I made the mount with a flat piece of steel which I rolled the edges to a 90* bend on and a piece of angle steel bolted to the sides and viola! I also opened the holes in the sides of the main mount to give some adjustability to it. On the floorboard there are two small raided channels which I welded the side plates to on the left, then on the right side it was close enough to the center tunnel that I just put one longer weld on it. Bada-bing - we got gas!

Always open to ideas and suggestions so feel free to chime in... Here are a few pictures until the vides finishes~
Thanks!
J

[BoxsterLS376]

Here is my pedal mount stuffs~
Thanks
J

[BoxsterLS376]

***EDITED 4/12/2015***
DO NOT USE THESE SPACERS - OTHER CLEARANCE ISSUES ARISE
MY BAD!!!!
BoxsterLS376
J
**********************
For these who wanted to know more about the transmission mount spacers I made here ya go~ These are a bit crude as I could only get 1/2" aluminum plate and not a bar but they will do the job. Just basically drilled the appropriate sized holed in the drill press then cut the spacers to size. I'll probably make another set later once I get some aluminum bar or may make some out of round bar... hmmm yeah I think i'll make the next ones round to match the mounts!

Thanks
J

[Pdwight]

would a stack of fender washers work ?? , you could tailor the thickness

[BoxsterLS376]

Originally Posted by Pdwight

would a stack of fender washers work ?? , you could tailor the thickness

What are you working on that you have 10mm fender washers laying around from?!?! Just kidding~ Yeah as long as they are large enough I'm sure that would work! I started off going that route but decided to go with a chunk of aluminum in the end for a bit of an easier installation and somewhat cleaner look
J

[Pdwight]

Here...good stuff

Metric Flat Washers: Large OD - Stainless Steel A2 | Mr. Metric

[Lcrivers816]

Question... What is the "custom throw out bearing" from Renegade? I hope it doesn't mean I have to get the clutch from them... I was going to buy a Spec clutch. :ah:

[BoxsterLS376]

Originally Posted by Lcrivers816

Question... What is the "custom throw out bearing" from Renegade? I hope it doesn't mean I have to get the clutch from them... I was going to buy a Spec clutch. :ah:

I think custom just means it is going to fit the high performance clutch setup~ not that there is anything really custom about it... if memory serves I believe it is just a new Sachs unit for a 996 but didn't really think about it.

You may want to contact Kennedy Engineered products before getting a SPEC clutch, they make the adapter plate and may give you a better price if you call them direct.
J

[BoxsterLS376]

Another quick update and video~ Spent some time working on relocating the throttle body and intake system... I think it's gonna work but i'll know for sure this weekend~

Video available here when it is done uploading - http://youtu.be/iyI4i_ilrIs

Goodnight folks~
J

[martsink]

Originally Posted by BoxsterLS376

Another quick update and video~ Spent some time working on relocating the throttle body and intake system... I think it's gonna work but i'll know for sure this weekend~

Video available here when it is done uploading - http://youtu.be/iyI4i_ilrIs

Goodnight folks~
J

Excellent video as usual. Where can I access these intake requirements from GM?

Also, have you considered mounting the TB on the intake manifold and using something like this tight elbow http://www.intakehoses.com/mm5/merchant.mvc?Store_Code=I&Screen=PROD&Category_Cod e=CHEW&Product_Code=90CB40 Do you think it would clear?

[BoxsterLS376]

Originally Posted by martsink

Excellent video as usual. Where can I access these intake requirements from GM?

Also, have you considered mounting the TB on the intake manifold and using something like this tight elbow Intake Hoses, IntakeTubing, and Intake Clamps - Intakehoses.com Cobra Head Elbow 4" ID Do you think it would clear?

Those Cobra head elbows are pretty cool and **I thought at first it would work - but it won't**.

A few problems - Fitment and how/what you are attaching - these are rubber hoses which means you are intending to just mount the throttle body in the factory position. On my current mounting setup with the Renegade kit, I have right at 7" inches from the intake manifold to the absolute back of the car. Once you add the throttle body onto the manifold you lose an additional 2" inches of clearance leaving 5" inches between the furthest point a hose will fit onto the throttle body and the rear firewall... Looking at their measurements figure "C" is the most critical and as you can see it is 6.44" inches long which just won't work.

Ok so I thought just make some flanges to attach to the intake and remote hang the throttle body like I did (although it would be hanging by rubber and not a metal pipe so you would need to make a support bracket). So you would still need to make flanges and weld them to at least a short section of pipe in order to attach it to the intake plenum and the throttle body with hose clamps. I think that may work... but again now you have a different problem - the intake to throttle body pipe is 3.5" inches and it does not look like they make a 3.5" cobra elbow Perhaps a different option?

Plus I'm not sure how much those cost, but in all reality the way I did it is fairly inexpensive... I bough extra of some things as it work out cheaper in the long run - but here is a quick breakdown of my costs off the top of my head:

$30 - Custom flanges cut by local fabricator (had 4 made for $60 - have 2 extra ;D )
$49 - 3.5" 120 degree mandrel bent stainless steel pipe
$52 - 4" silicon coupler kit with clamps (5 couplers and 10 clamps, should only need 3)
$22 - 1 foot of 4" straight stainless steel pipe
$44 - 4" Aluminum 90 degree mandrel bent pipe

So I've got about $197 plus time, cutting and welding materials/tools~

Hope this info helps and good luck with your project!!!!
J

[BoxsterLS376]

[QUOTE=martsink;438566]Excellent video as usual. Where can I access these intake requirements from GM?
QUOTE]

Got so involved with the cobra head thing I forgot to address this! THANKS! I realize I'm no Jeremy Clarkson but if they can help you out then they have served their purpose

The requirements came with the GM crate motor stuff but could probably be found online if you look hard enough... but this picture may help - bottom left~
Take care~
J

[martsink]

[QUOTE=BoxsterLS376;438842][QUOTE=martsink;438566]Excellent video as usual. Where can I access these intake requirements from GM?
QUOTE]

Got so involved with the cobra head thing I forgot to address this! THANKS! I realize I'm no Jeremy Clarkson but if they can help you out then they have served their purpose

The requirements came with the GM crate motor stuff but could probably be found online if you look hard enough... but this picture may help - bottom left~
Take care~
J


Thanks so much!

[BoxsterLS376]

Originally Posted by BoxsterLS376

Those Cobra head elbows are pretty cool and **I thought at first it would work - but it won't**.

A few problems - Fitment and how/what you are attaching - these are rubber hoses which means you are intending to just mount the throttle body in the factory position. On my current mounting setup with the Renegade kit, I have right at 7" inches from the intake manifold to the absolute back of the car. Once you add the throttle body onto the manifold you lose an additional 2" inches of clearance leaving 5" inches between the furthest point a hose will fit onto the throttle body and the rear firewall... Looking at their measurements figure "C" is the most critical and as you can see it is 6.44" inches long which just won't work.

Ok so I thought just make some flanges to attach to the intake and remote hang the throttle body like I did (although it would be hanging by rubber and not a metal pipe so you would need to make a support bracket). So you would still need to make flanges and weld them to at least a short section of pipe in order to attach it to the intake plenum and the throttle body with hose clamps. I think that may work... but again now you have a different problem - the intake to throttle body pipe is 3.5" inches and it does not look like they make a 3.5" cobra elbow Perhaps a different option?

Plus I'm not sure how much those cost, but in all reality the way I did it is fairly inexpensive... I bough extra of some things as it work out cheaper in the long run - but here is a quick breakdown of my costs off the top of my head:

$30 - Custom flanges cut by local fabricator (had 4 made for $60 - have 2 extra ;D )
$49 - 3.5" 120 degree mandrel bent stainless steel pipe
$52 - 4" silicon coupler kit with clamps (5 couplers and 10 clamps, should only need 3)
$22 - 1 foot of 4" straight stainless steel pipe
$44 - 4" Aluminum 90 degree mandrel bent pipe

So I've got about $197 plus time, cutting and welding materials/tools~

Hope this info helps and good luck with your project!!!!
J

Hey everyone,
So apparently my head was up my butt this morning when I looked at these Cobra intake hoses but this could very well be a viable option for this swap!! Vlad was kind enough to correct me without making me feel too bad But this is good info so wanted to make sure I wasn't spreading bad info out there.

I stand corrected and here is some good info
Thanks Vlad!
John

Originally Posted by martsink

Hey,
Thanks so much for getting back regarding my intake comment. I did't want to highjack your thread, so I figured its more appropriate to PM you. On the cobra inake hose, you mentioned the "C" measurement, but what if you mount it the other way and look at "G"? The total width is 4.94 inches, which would be a pretty tight fit, but it should work. I drew a little diagram here. Let me know if I am missing something in this logic.

Heres a link to the cobra hose

Thanks,

Vlad

Hey Vlad,

Wow I dunno what I was looking at this morning - my only excuse is that I'm at work and too much multitasking got my eyes confused

You are totally correct - for some reason I was thinking the "C" measurement was the "G" measurement. DOH!!

Ok so taking that into consideration it may work but will be VERY tight. In looking at mine I think it will clear the fuel line which mounts on that back wall but you could always relocate that if needed. Also you may want to check on the measurement for the throttle body you are going to be using. You may also be able to shorten the "B" spout to get a bit more clearance.

I just noticed the price on the site too... for that price I don't think you can afford to not try it!

I'm going to repost this into my thread anyway as it could be useful to someone else!!

Thanks!
J

[martsink]

Cheers!!!