Build thread - 2001 base Boxster
 

Figured I'd start a build thread to collect miscellaneous questions, photos, and hopefully guides.

Car:


2001 Porsche Boxster, pretty well equipped. Highlights of factory options:

- Manual Trans
- 17" turbo twists
- sport seats
- Heated Seats (power recline)
- sport design package
- M535 alarm (curse you original buyer....)
- Hi Fi sound
- Wind deflector, storage

I bought the car with a seized motor, swapped a "new" one in. "New" motor had 6 of 12 exhaust bolts broken when it arrived from the salvage yard. Bought a welder, retaught myself to weld (studied Mechanical engineering in college some 12 years ago, and took some machining, manufacturing classes), broke the bolts further and further, bought the stromski kit, spent 2 days drilling out the now hardened bolts. Tungsten carbide bits are the way. Replaced most of the accessories (starter, alternator, tstat, water pump), cleaned and replaced tons of accessories. New flywheel, new clutch. New RMS. New motor mounts, new transmission mounts. Paid a shop to put new continental DWS06s on. Sheesh. $1000 for rubber!

Car has 144K on it, and the chips on the hood suggest a tailgater. Spent 12 hours sanding, polishing, buffing, ceramic coating. I didn't overfill the chips (which is what I should have done), but looks miles better than it was. probably 300+ chips :|. Will need a paint job in the next couple years.

Replaced brake switch, replaced ignition switch. "Fixed" HVAC foam.

Changed to a chinese 986 dual muffler exhaust. little droney so added those DB killers. It no longer burbles on downshifts/clutch ins! I might have to pull them back out, or take out the center section.

Repacked the CV Joints. Changed gear fluid (those "classic" porsche gearbox cans are hilarious). Changed out all those gearbox parts Pelican recommended (guide tube, clutch release lver, pivot, etc.). Replaced some of the underbelly shields, windguards, damaged fasteners in trunk, frunk.

Did oil change, drove 250 miles, did a second oil change! Passed the damn OBD EPA monitors (took like 150 miles).

Just replaced condensers, drier, and had a shop evacuate and charge. Ice cold! Hopefully it doesn't leak (they said it held vacuum so I am hopeful).

Plastic window was missing when i bought - sewed a new one in (little baggy, but could do better next time around)! I generally don't take it out with the top up.


To do:

1. Reupholster seats. Ordered from lseats. I reupholstered my truck (5th gen ranger) with leather to great success, so am hopeful that the boxster looks as good.
2. Trim - need to pull roll bar, a few other bits to repaint the sport silver. Painted the radio, some of the door trim already. Will pull center console as well.
3. Audio - I bought a 987 front passenger footwell sub. I think by pulling the carpeting I can make this work as a "factory" option. I also ordered some super paulie speaker mounts, and will add them to the storage shelf. I've got a PCCM clone on the way (ordered 2.5 weeks ago, might arrive this week).
4. Door latches - Curse the M535. When pulling handle, the window drops, and as soon as i release it shoots up. Clearly the door latches (both sides) are sticking "closed." I can finagle them a bit and get it to realize the door is open, so maybe a clean + relube, but I've got junkyard parts to swap in. I cannot afford $1100 for the factory latches. I also don't get a chime on leaving the headlights on, so think it is a doorlatch issue causing that.
5. sandblast & powder coat wheels at some point. They are chipped in a few places. having just paid to have these mounted/balanced not in a rush to do this.


Few initial photos to follow.




http://986forum.com/forums/uploads02...1750727523.jpg


http://986forum.com/forums/uploads02...1750727573.jpg


http://986forum.com/forums/uploads02...1750727587.jpg


http://986forum.com/forums/uploads02...1750727598.jpg

Hmmm, a lot of that sounds really familiar, I have done almost all that on one or another of the 3 Boxsters that have passed through (or are still on) my hands.
On the door latches, when you pull them check that the solder traces are not cracked, I had similar symptoms and resoldering fixed it up.

Great point. Suspension needs a refresh (starting with stabilizer links but will be replacing shocks, struts, tie rods, control arms, sway bushings next spring), and our roads are rough. Previous owner was a solo driver it seems so it didn’t make sense both sides were worn (the other failure point I’ve seen talked about is wear on the latch lobe that actuates the switch).

No AOS replace? No IMS?

Replaced the AOS (and inspected, replaced vac lines depending on condition). Did not do IMS. Spending $1900 for the fix on an engine that cost damn near that from the salvage yard didn't make financial sense to me. My memory is hazy but it was 80-90K mileage on the yard engine. Consensus from what I was seeing is that IMS failures were typically earlier, high mileage motors likely were fine.

If I pull for a clutch/something else in the next few years I may emotionally, stupidly drop big money for it.