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Old 06-26-2019, 08:59 PM   #1
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2002 S - Weekend/Track Build

A couple weeks ago I picked up a 2002 Boxster S 6-spd with 78,000 miles for $4100. Runs great, new clutch, clean Carfax, but the previous owner was apparently not too careful and had a couple parking lot incidents which he attempted to fix himself. This doesn't bother me too much, it looks mostly straight, just some areas of uneven Bondo that isn't perfectly smooth. Oh well, I'm going to be beating it up at the track anyway. Runs smooth, drives straight, shifts smooth into all gears, etc, etc.


Things are already rolling as far as maintenance and modifications go. Going to be focusing mostly on reliability, handling, and a mild power increase.

As it sits now (this photo will be updated whenever I make a change):

Last edited by Superbike81; 06-26-2019 at 09:10 PM.
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Old 06-26-2019, 09:05 PM   #2
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The day I picked it up, after driving three and a half hours home from near Portland.






Got it up on the QuickJack right away to start doing maintenance and finding out exactly what is needed.




First mod came in today, wheels and tires! OZ Alleggerita 18x8.5 and 18x10 on Michelin Pilot Sport 4S 225 front 265 rear.
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Old 06-26-2019, 09:09 PM   #3
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Biggest issue for me is being 6'3". Fortunately I've got a great race shop nearby called 425 Motorsports. They carry just about every popular aftermarket seat at the store to try out. I found that the best fit for me was this OMP. The Recaro that everyone recommends was too tight around my shoulders.

They are fabricating me up something similar to the Brey Krause floor mount right now, I'll go pick it up on Saturday. With it just sitting straight on the floor I can barely see over the steering wheel, haha.

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Old 06-26-2019, 09:37 PM   #4
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Originally Posted by Superbike81 View Post
Biggest issue for me is being 6'3". Fortunately I've got a great race shop nearby called 425 Motorsports. They carry just about every popular aftermarket seat at the store to try out. I found that the best fit for me was this OMP. The Recaro that everyone recommends was too tight around my shoulders.

They are fabricating me up something similar to the Brey Krause floor mount right now, I'll go pick it up on Saturday. With it just sitting straight on the floor I can barely see over the steering wheel, haha.

I tracked a Boxster S for several years -- first thing I did was put a 1/2 qt deep sump and an EBS baffle plate in -- very do it your own.
Second was add a BK roll bar extension and pads

Then replaced the brake fluid with racing fluid of your choice. get the gt3 brake ducts.

Change the gear oil.

I also put a 4"crank pulley on the car.

I quickly swapped the suspension for a used SPB suspension -- and it made a world of difference.

Sadly I sold the car -- but the only issues I had was a slave cylinder and the pins inside the tranny gave out. I had a friend put 6 new ones in at $1 a piece -- no problems after that.
I think if you added a tranny cooler, that might alleviate some of the issues.

That was on a 100,000 mile car and 10000 more track miles.

I very much regret selling that car.

Mike
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Old 06-27-2019, 05:37 PM   #5
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Quote:
Originally Posted by seningen View Post
I tracked a Boxster S for several years -- first thing I did was put a 1/2 qt deep sump and an EBS baffle plate in -- very do it your own.
Second was add a BK roll bar extension and pads

Then replaced the brake fluid with racing fluid of your choice. get the gt3 brake ducts.

Change the gear oil.

I also put a 4"crank pulley on the car.

I quickly swapped the suspension for a used SPB suspension -- and it made a world of difference.

Sadly I sold the car -- but the only issues I had was a slave cylinder and the pins inside the tranny gave out. I had a friend put 6 new ones in at $1 a piece -- no problems after that.
I think if you added a tranny cooler, that might alleviate some of the issues.

That was on a 100,000 mile car and 10000 more track miles.

I very much regret selling that car.

Mike
Thanks for the information!

I've got suspension (Feal Coilovers) on order, they are custom built to spec, should be here in a couple weeks.

Brake fluid flush and transmission fluid change are coming soon.

I thought about oiling issues, but wasn't aware of the products you are talking about. I'll likely go with a full solution that includes baffles, additional capacity, etc. Transmission cooler is under consideration as well, probably next year though. Thanks!

The crank pulley is something I'm considering, but it can wait a little while, maybe until next track season.

For now I'll be doing a couple of HPDE days and a non-affiliated AutoX event or two, still learning the car, so I'm not overly concerned with oiling issues.

Last edited by Superbike81; 06-27-2019 at 05:40 PM.
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Old 06-27-2019, 06:49 PM   #6
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Originally Posted by Superbike81 View Post
A couple weeks ago I picked up a 2002 Boxster S 6-spd with 78,000 miles for $4100. Runs great, new clutch, clean Carfax, but the previous owner was apparently not too careful and had a couple parking lot incidents which he attempted to fix himself. This doesn't bother me too much, it looks mostly straight, just some areas of uneven Bondo that isn't perfectly smooth. Oh well, I'm going to be beating it up at the track anyway. Runs smooth, drives straight, shifts smooth into all gears, etc, etc.


Things are already rolling as far as maintenance and modifications go. Going to be focusing mostly on reliability, handling, and a mild power increase.

As it sits now (this photo will be updated whenever I make a change):
I regard the wheels as an improvement!
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Old 06-27-2019, 07:06 PM   #7
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Originally Posted by Superbike81 View Post

I thought about oiling issues, but wasn't aware of the products you are talking about. I'll likely go with a full solution that includes baffles, additional capacity, etc. Transmission cooler is under consideration as well, probably next year though. Thanks!

The crank pulley is something I'm considering, but it can wait a little while, maybe until next track season.
The sump and baffle that seningen mentioned are what I use, and while they address the M96 engines oiling issues somewhat, there are still issues around the oiling. The trick seems to be to not use R-compound tires, and in long left-hand sweepers you can get oil starvation and huff the engine.

The crank pulley should be one of the first things you do, as it will slow down the power steering pump, which can overheat at extended track day revs. I ran a bunch of track days with my 2002 2.7 and never had an issue, but thought that it would be prudent to not take any chances and got the smaller pulley.
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Old Yesterday, 08:08 AM   #8
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Been busy the last couple of weeks.

- Feal Coilovers installed (actually only driver's side so far, should finish the rest this weekend)
- Gloss white vinyl wrap mostly complete, need to clean up a couple areas.
- Etsy sourced Martini livery/graphics were a big fail, quality was not good and side stripes weren't even long enough, hunting for a local shop to do it for me.
- Ordered Tarett front/rear drop-links, Rennline toe arms, Rennline wheel studs, H&R 7mm spacers rear & 15mm spacers front (will remove for track use), Rennline tow hook, and a few other little things.
- Plastidipped wheels red, if I end up liking it enough I'll powdercoat them red next time I have to do a tire change.
- Hawk brake pads front and rear
- Ended up changing directions on the seats, went with something less aggressive (Corbeau RRX)
- Lots of little maintenance items, checking torque specs, flushed brake fluid, etc

Hoping to finish installing all the suspension stuff this weekend so I can get the car in for an alignment. The rear suspension install is a pain in the butt.


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