Nice! Well done....weight savings and no faded carpet I am very interested!

What are the merits of Lexan vs plexi....other than weight

Some sort of Dzus fastener would be great....flush heads that won't fret the rear window

Wow, that is really good. LED lights really show it off too.

That's what they're called?! Thank you, I've been looking for those but didn't know what the name was.

Why did I clean my engine?
 

Another quick update:

I've received most of the seals this weekend and have already narrowed them down to two contenders. This weekend I'll use them both and decide which one is better.

I've also received the mounting hardware with silver and black chrome caps, BUT... Thanks to Jaykay's comment I now know what the OEM fasteners are called. As a result, I've decided to scrap the original hardware and find a set of Dzus fasteners that will allow for cover swapping without a need to change mounting clips.

On the side, I've been working on the LED strips for the covers and finding a reasonably priced source for them. Tracking down the female connector that plugs into the car's defroster harness has been a ************************. I've found someone in the UK that stocks it, but they have a minimum order quantity of 200. I'll probably bite the bullet on this one and go ahead with the order.

Lastly, I've received my first batch of quarter inch plexiglass for forming. I am also experimenting with half inch plexiglass for additional sound deadening, heat resistance, and strength. The only issue with the larger plastic is that it is double the price... And forming it is a complete PITA.

I expect sometime early to mid February I should have the first couple of covers done and the rest shortly after.

Of course, I want to say thank you to everyone for the kind words and continuing support!

Dibsies on the first half inch prototype with the Dzusbobs connectors

Long time lurker, first time poster. That being said I really appreciate that someone has put in the time and effort into a mod that will let us display our engines proudly. The Boxster engine may have its quirks but I've always felt that a vehicle's engine is its heart. The one thing that had bothered me about the Boxster's design is that it is difficult to show off what makes it GO. I for one am very interested in how this plays out. Thank you to the OP and thanks to everyone else on this great forum who has made owning my Porsche a little easier with all the insight and tips.

Seriously cool! Has me thinking it would be worth removing the Bose soundbar... I would consider a buy!

Looks great! Very interested. thanks for the updates

ready to order
 

If you start a new thread for ordering please post a link back here. Sounds like you have your first group buy. I count at least 15 so far. I'm in!

Shoot, you can upgrade the dash & door speakers, get a better 4 channel amp and call it even. :)

awesome job!

So are you at the final iteration of this project so that those that are interested can now order something?

Yes please, let us order

depending on the price im in, if not now for sure in time for summer motoring!

Why did I clean my engine?
 

Hasty hasty :P
I'm working as fast as I can but I also have a full time job which I'm now working 6 days a week to meet deadlines for animal testing and license filings.

The engine covers are being laser cut but to keep costs down, the turn-around time is on the order of days. Once everything reaches my doorstep I can make quick work of forming and assembly. Until then, all I can do is review the design.

To your question... Yup, I've frozen the physical design, picked the seals I want, and I'm negotiating with a supplier for all the Dzus connectors that will be needed.

I can take orders now if I wanted since I've already paid for enough material to make 20 units. The reason I haven't formally started accepting orders is because I don't want anyone to have paid without an engine cover already available to ship.

If you're worried that I might decide not to continue with this, don't be. I know everyone is anxious but I'd rather delay shipping by a week than have dozens of unsatisfied buyers.

I’ll take one if you add a transparency like this.

http://986forum.com/forums/uploads01...1391565202.jpg

I wasn't anxious about whether you would continue or when units might be available to ship. I was just reading the thread and couldn't see whether this had progressed to the point of being available for sale. I am interested, so once everything is nailed down, would you please PM me with costs and any available options.

I’ll take one if you add a transparency like this.

Hey Jager - are you planning on getting one on your mate Johnny Danger????:p

In fact JD's been very quiet for the last few weeks - perhaps he's hibernating or planning a clear Lexsan engine lid upgrade with acid yellow LED's.........

Groovy man......an option to have the rear speaker and storage deck on or off would be great....I think it would look pretty good but it's hard to know until you try it. I imagine you would have to source the same style locking pins as stock and fasten them through/on the cover. They are like studs with tangs on them as I recall. They should also look good with the storage box off.

Sorry to disrupt your fastener plans but quick removal of the engine cover is probably a good feature. Dzus fasteners have a very coarse spiral such that they come off in a turn. Perhaps they won't look as good as what you had planned. I have run with a bare stock engine cover and it's thin and buzzy....the heat shield underneath perhaps. If the fasteners have some sort of fold down D-ring on the head it might be prudent to ensure that they have a tight friction fit ....are hard to move so that they don't buzz around loosely

Keep up the great work!

There was a company that made something similar a while back. In my opinion the m96 motors don't look that great to show off. It probably sounds great though.

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Please let us know the results, since we're already drooling for this cool mod to group buy/make!
[QUOTE=Shehadehd;383727]Another quick update:

I've received most of the seals this weekend and have already narrowed them down to two contenders. This weekend I'll use them both and decide which one is better.

Why did I clean my engine?
 

Someone here posted the cover I think you're talking about... It was for the cayman and looks good if you keep the engine clean.

I actually think the m96 flat six design makes the engine look pretty nice. If we're comparing it to old school V8s and super car v10/12s then I totally agree with you. But for what it is, I like the m96 more than a lot of other engines in its class.

JayKay: the Dzus connectors I've been looking at have rubber lined rings so they don't rattle or scratch the cover. I've also been looking in hex key connector.

Leon: I've found the right seal for the covers. Now I'm waiting for the first batch of laser cut covers

My '99 Boxster is up on a lift right now, and this thread got me thinking (always dangerous) - do you know if with the soft top down and the hardtop on, would you still be able to see the engine or would the folded soft top obscure the view?

You'll only be able to see the engine through this angle

http://img.tapatalk.com/d/14/02/06/4uhahapu.jpg
http://img.tapatalk.com/d/14/02/06/amypa9em.jpg

The soft top blocks the ability to see it from the rear view window.

You are right... JD does not move as fast during the cold winter months plus he goes to bed much earlier this time of year.

I wonder if he saw his shadow?

Why did I clean my engine?
 

I've gotten the first batch of acrylic covers. They look good so far. I'll be forming them and installing the necessary pieces throughout the week and will have the first couple ready soon.

On a separate note, Since cutting the acrylic leaves a lot of odd sized pieces that Ive already paid for, I've decided to use them for this.

http://img.tapatalk.com/d/14/02/11/hu9ubavy.jpg
http://img.tapatalk.com/d/14/02/11/u4yby5y5.jpg
http://img.tapatalk.com/d/14/02/11/ahamuzed.jpg

It works surprisingly well. I just need the rubber boot in the opening to grip the smaller sized cups. I think after an iteration or two, it'll be perfect for anyone without a cup holder... I just got to find an elegant way to keep the arm rest lid open. I'm thinking of a spring or rubber rod that wants to swing it open. That way you when you press the button, it'll open like the ashtray.

When you form the covers, is there any room for you to mold the cover so there is more room under it? After installing my supercharger kit, the stock cover hits the intake pipe slightly and would work way better if there was more room.

http://986forum.com/forums/uploads01...1390094765.jpg

http://986forum.com/forums/uploads01...1390094800.jpg

http://986forum.com/forums/uploads01...1390094870.jpg

The next time you have access to the engine can you take a photo that's level with the pipe so I can see how high it raises up above the cover edges; both from the side and from the back.

you could always just remove the soft top all together and put on a hard top.

Since shehadehd is a grandpa, he probably will opt to just take his softtop out and keep the hardtop on; he's never gonna put that GAHH knockoff on anyways ;)

Shehadehd, is that 1/8" plexi? I thought you were prototyping a 0.5" cover? Also, can you PM me the final material you chose for the seal? (Or post publicly if you are comfortable)?

Why did I clean my engine?
 

No and no. That's the quarter inch plexi and the 0.5inch is far overkill. you'd be better off sticking with 0.25 and switching to impact acrylic or lexan. Kids these days...

0.25" seems potentially unsafe. What if I'm in an accident? Will this cover cut my head off?


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Why did I clean my engine?
 

It's inherent that the plexiglass is not as strong of a material as the OEM cover with two layers of carpeting. Also, I do not claim to have a safety rating for it. I am simply doing my best to create a cover that will not melt nor shatter from normal wear and tear. Hence why I have spent the last month making a number of these looking for the best material I can reasonably offer.

What happens during an accident is out of my control and frankly I do not , and probably will never, crash test the covers in a controlled environment. It may hold up just fine in an accident or it may break apart. If the engine decides to fly out of the engine bay, I cannot say this will do much to stop it. If you want to say that 0.5" is better... You are right. Bulletproof lexan is even better still... But unless someone requests and is willing to pay for the double or triple price markup of these materials, I cannot use them.

I'll be more than willing to bet that aftermarket parts like bumpers and spoilers don't claim they can't harm you in an accident. Even a windshield mounted gps or phone stand can kill you in a collision. The truth is that the engine cover I'm making is similar to other aftermarket parts. It's an aesthetic attempt to bring-out a hidden gem in our cars. With that being said, I'm using the best parts I can reasonably find to give it a level of quality. Expecting anything more is a miscommunication between me and you guys.

With that out in the open, if anyone else wants to opt out please let me know because I'm going to have 20 covers made next week and if this number should be half, I need to tell the supplier soon. Sorry if this is news to you guys.

i wouldnt imagine this to be any less safe.

If you get hit hard enough to dislodge the engine cover which is in the middle of the car, you probably have much bigger worries. It is not a structural piece, and you have a roll bar, and seat between you and it. The covers main purpose is to act as a firewall, which plexiglass is not great for. But I have also never heard of a 986 having an engine fire.

If you are rocking a hardtop, it is only 4 bolts and some connectors to pull the soft top out of the car, so you can show the engine off.

Very cool mod, and Shehadehd is doing a great job! It is always awesome when some is willing to manufacture a popular modification for everyone to enjoy! :cheers:

It is better to remain silent and be thought a fool......

Lets give this fella the benefit of the doubt and assume he is being facetious and not a complete nut. I enjoyed the disclaimer that this prompted though, very entertaining. Come on guys…. Obviously 0.5” Lexan is has more mass than 0.25” and taking into account newton’s second law the 0.5” is capable of doing more damage to your head. I say use 0.125”!!!

:)

wow... me likey. i just showed my wife the pictures and beg for a valentine's gift. keep me posted please.