Boxster V8 project log

[Marc_986]

I ordered one of the plastic covers for the brake reservoir of a RHD car. It was cheap, so shipping costs a bit of time, but I might get it later this week.

Old brake line is removed, new one is waiting for me at the dealer. Gave me some time to look at the parts on the wreck. I can't use that subframe is it has the additional bolts to the chassis. Was looking at that because one threaded hole in my subframe is damaged from removal of the bolt. Well, I think it was already damaged by the looks of the stuff that came out. Looks like it was glued in place. Anyway, it shouldn't be too hard to repair the threads, or rather drill it out and tap it one size bigger.

The front ARB was removed from the wreck and this is the 24mm one. So I need to think which one to place on my car. Leaning towards the thicker one, accepting the increased understeer for the time, until I swap the rear one out. This does feel a bit better to me as I still need to get to know the car.

Also I looked at the wiring diagram of both cars. As far as I can see F7 (in the power distribution box) should not be present in my car. So I can either use this for the additional fuse required by the ABS, or I can use it for the power steering pump. My first thought is that it is most tidy to use it for the power steering and tap the additional ABS power from one of the unused fuses in the fusebox.

[Marc_986]

Little update on this project. I picked up the new brakes lines and some small clips and pieces at the dealer today.

First of, get the front brake line in place together with the new clips (one was broken on removal of the old line, the other looked poor as well). Also the small lines from MC to ABS unit were mounted.



The plastic cover for the RHD brake reservoir also arrived, so I could position it and see what it brings. Actually, quite a lot of space within this cover. Unfortunately though, not fitting the volvo pump. For this to work, I probably need a Jeep / Dodge pump or something alike. I'd also need to sort out where to take the line from the inside to the outside. Most likely run it across close to the ABS unit and drill some holes to feed it down from there.



The other idea in my mind required removal of the bumper cover. Easy enough, so off it went. I placed the third radiator for fitting and surely enough, no way to fit the power steering pump as well. However, without this third radiator, there is a lot of space to fit the pump:



And the position is perfect for a short hose to the steering rack, with a nice channel available for routing the hoses:



It looks like a no-brainer to mount it there. The only thing that doesn't feel right is that minor accidents which would normally only require a new bumper + cover will now likely slamp the pump into the frunk. Not a safety concern, but damage from small accidents can be quite more significant.

So open for input while I also let it rest for a moment to consider this. As it stands I'll either need to get myself a different pump and mount it under this RHD cover, or just go for front bumper cover location.

[Gilles]

I would have retain the center cooling radiator for the V8 engine and install the electric power steering pump inside the frunk, IMHO you would need as much cooling capacity as you can get to cool a V8..

[Marc_986]

There are quite a few cars with the power steering pump mounted horizontally. I wonder why I couldn't do the same with a volvo pump (I'd need the one for external reservoir, but otherwise they are the same).

Horizontally, it would fit in the frunk, below the plastic trim piece, easily...

[Marc_986]

So, I've been thinking a bit. Seeing many conversions where people have put the pump in the wheel arch (most of the time in front of the wheel), why not do something similar?

So obviously the front is not going to work, it is already tight enough with the radiators there and some space for the air to flow.

But, at the rear of the drivers side front wheel, there is only the windscreen washer bottle. A quick look leads me to believe there is enough space to fit a power steering pump there. Still the rack is close, the reservoir can be put where we currently have the washer bottle filler neck.




If this all fits, I would then only have to find a washer bottle which I can mount, preferably, on the right side of the battery. That would leave the frunk nice and empty...

Any thoughts?

[Marc_986]

Managed to find some time to continue this story. Picked up a remanufactured steering rack for a good price at a specialist shop. So that'll go in once the other aspects are covered.

I made a 'bracket' out of some sheet aluminium I had around. Bend by hand and cut with some tin snips. It is now inserted in the same holes that normally hold the washer bottle (I had a spare washer bottle around from which I cut the pins that go into those holes). It is not perfect, but does allow me to continue measuring and fitting. I removed the reservoir of the pump as the remote reservoir units are only slightly larger than the bare pump itself.

Shot from below, so you can see where it might sit:


From the side a view of the top. I should be able to get the hose routed in to the remote reservoir (which would still be higher than the pump).


Not complete without trying to fit the liner back. As you can see I need to rotate the pump a bit (it is mainly the cut pressure line that pushes on the liner) and might need to move it up slightly more. Also it looks like I can reduce the tilt a bit. The bump in the liner looks significant, but that is partly due to it pushing the side away from the bodywork.


Christmas period is upon us shortly, but I hope I can make a few iterations and get it to fit. Hose routing doesn't seem too difficult (yet).

[Marc_986]

Played a bit more with positioning of the pump. It is a bit tight, but I'm quite positive it'll fit. So I ordered a pump with remote reservoir and which includes the volvo bracket and rubber suspension things. Maybe that helps a bit towards the final positioning and bracket.

Meanwhile I have taken the Boxter S cooland pipes out of the wreck as well as the coolant pipes out of my base car. I didn't quite imagine the difference would be so large:


Looking at the area of the pipes on left / right sides, it is a very significant difference:


Another thing I didn't realize is that basically everything between the engine and radiators is different in diameter. So not just these pipes and relevant hoses, but also the short pieces of pipe in the wheel wells and hoses to the radiators.

I'll keep my car double radiator for now, so I need to find two additional hoses (as I won't be using the T-junction hoses towards the third radiator). All other parts (including clamps / brackets etc.) I can just transfer from the wreck

[Gilles]

Mark, the pictures of the metal cooling pipes, one comes from a Base boxter and the other from the S model..? If so, then the difference is impressive!