As you said, it’s a real challenge, and unless I quit my job, I won’t have enough free time to work on it.
I already designed the plenum back when I had plenty of free time ;)

I keep that in a corner of my head ;)


Ben

You can install the motorsport aos if you want a solution.

True !
But if I remember that’s quite an expensive upgrade !

I fitted a 74mm throttle body and plenum from a 996 for not a lot of money to my 2001 Boxster S. I purchased a silicone elbow/reducer off eBay, a piece of aluminum tubing, and another silicone coupler to connect to the stock intake which was trimmed. all for under $100. Tuned ECU for larger TB.


http://986forum.com/forums/uploads02...1530316586.jpg

jd,

Good job! I'm inspired to replicate your project

Very true, but if someone wants a solution, its there :-)

And ? Noticeable results?
How'd you tune the ecm? DIY? Or Take it to somebody?

Sent from my SM-G930T using Tapatalk

Yes, it's a well known mod. But it's looks a bit too "hacked" for my liking.


Ben

https://i53.servimg.com/u/f53/13/27/...h/img_3610.jpg

More coming soon ;)

Wow! Looks amazing.

https://i53.servimg.com/u/f53/13/27/76/86/img_3616.jpg
https://i53.servimg.com/u/f53/13/27/76/86/img_3615.jpg

I received it today. It's just the prototype, so there are a few things that will need to be looked at. But man it looks and feels good ! That thing will handle anything you throw at it !

So... almost done !

https://i53.servimg.com/u/f53/13/27/76/86/img_5314.jpg
https://i53.servimg.com/u/f53/13/27/76/86/img_5316.jpg
https://i53.servimg.com/u/f53/13/27/76/86/img_5313.jpg

What kind of tune ?

That is beautiful! Is this the final product?

Freeing up the power potential on the 3.2 S
 

Hey Guys, I'm new to the Boxster world but have owned several other Porsche's from the air-cooled era. Not to worry, I sold them out before they became ridiculously valuable so I could retain my original buy high, sell low strategy. :)

My 2001 S is crazy clean, like near showroom (probably never spent a night outdoors in its 42,000 miles traveled), but I would like to capture it's full potential if possible. I drove it straight to the professionals upon purchase to have the IMS bearing replaced for peace-of-mind for starters.

My question is, can I change the headers, cats & mid-pipes, plenum, throttle valve and air box without sending the ECU into protest via check-engine light? My plan is to retain the stock outward appearance and not compromise practicality. If it's possible, I'll commit, if not I'll continue to live with the strangled 250HP.

Please pardon the self-serving promotion:

http://986forum.com/forums/boxster-cayman-parts-sale-wanted/73195-sale-hollowed-oem-exhaust-manifolds-complete-mini-cats.html

The carbon fiber part yes, the plastic flange no, it'll be slimmer and better looking ;)


Yes you can do all that without a tune and without getting a CEL.
Install cheaters for the secondary O2 sensors if you're going cat-less, that's all!


Ben

Freeing up the power potential on the 3.2 S
 

I've done a little research on the mods I posted about earlier. It looks like all of them are a long slide for a short gain; headers & exhaust for $4000-ish for 6HP, intake mods for $1000-ish for 6 more HP and a tune for $800 for about 6HP more than that. 18HP is a lot but $6000 is a lot more than that. Can anyone share their experience with these upgrades? What's the seat-of-the-pant dyno results? Should I just leave it alone? There has to be something- or a combination of things - that softened the potential of the 3.2 S, the specific output is considerably lower that other models of the same era.

You might take a look at my YouTube channel: https://www.youtube.com/user/12shoes2
I have covered all these mods in my videos and the result was quite noticable once I had everything in place and a tune done. I wanted to get a dyno done but unfortunately I threw a rod bolt on my last track day this fall and now I need a new engine. This engine failure had nothing to do with the mods that I made but stuff happens at the track.

That's a crazy high estimate for those particular mods. Divide it by four-ish, perhaps even more if you buy used as I had suggested to you earlier here.

To illustrate further, here's another idea for your consideration: http://986forum.com/forums/boxster-cayman-parts-sale-wanted/73389-sale-fabspeed-200-cell-986-header-%96-new-never-used.html

By the way - Out of respect for Ben's thread, you would be better served to start a new thread on your topic, rather than to continue to be off-topic here. You will likely gain a lot more traction and interest.

I can't speak for the exhaust/header gains as it seems like a small HP gains for the $$ invested (not cheap) but for little wrenching and small investment of couple hundred bucks you can do the 987 airbox, 996 TB, and 997 T as a single mod and I think you would be quite surprised. Power gains throughout the rpm range and wider smiles at least for me. Butt Dyno says to me about 10 -15 just my opinion. It's a different car and no Cels. Passes smog no problem. Bang for buck 👍 Hardest part is 987 airbox

Ben, is this for sale yet?

Is it for 82MM GT3 TB? Can it for into 996?

I'd suggest read the thread. all is revealed within..... ::spreading arms in an expansive way::

;)

Not for sale yet, I'm still waiting on that intake tube !
It's been more than a month now...

I finally received the temporary intake tube ! I will be fitting the plenum on Saturday :D

OOOH I'm excited :D

So... You know me by now ?
Nope, it's not fitted yet !

Though, the tubes are fitted !
https://i53.servimg.com/u/f53/13/27/76/86/img_6316.jpg
https://i53.servimg.com/u/f53/13/27/76/86/img_6315.jpg
https://i53.servimg.com/u/f53/13/27/76/86/img_6317.jpg
https://i53.servimg.com/u/f53/13/27/76/86/img_6319.jpg

Very happy with the result !

Dare I say it will be fitted this weekend ? hummm...

OK ! Late again, but it's IN !!!!

https://i53.servimg.com/u/f53/13/27/76/86/img_6519.jpg
https://i53.servimg.com/u/f53/13/27/76/86/img_6518.jpg
https://i53.servimg.com/u/f53/13/27/76/86/img_6517.jpg

I replaced the K&N filter too...
https://i53.servimg.com/u/f53/13/27/76/86/img_6520.jpg

I haven't driven it yet, just parked the car...
I know I'll have to wait a bit for the DME to adap to it, but I already know this is going to be awesome !

Fitment is perfect, everything goes in without trouble, the intake tube fits (very close, but it fits without touching !)
I've taken pictures of the install so I can have step by step instructions to include.

It's a prototype, so some things might change for the final version but it's mostly there :)



Ben

Quick update !

I've hit 600km with the new plenum and throttle body.
The DME has now fully adapted to the new parts, and I have to say that I love it !

First, the sound... I still have the stock muffler, and there is more intake noise than exhaust noise !
I have a RHD Boxster, so I'm driving on the wrong side... the airbox sitting in the passenger side, previously I was not hearing much intake noise...

Now ? I love it ! The sound is louder with a higher pitch, without being annoying ! It sounds way better throughout the rev range.

In terms of performance, it took a while to adapt (no tuning done for now) but now it's a blast, with a very noticeable improvement from 2000rpm and up !
The torque dip between 3 and 4000 rpm feels better than before, the engine is pulling very strongly from down low all the way to the redline !
If I should make one complaint, is that it's a bit more linear now if you floor it from down low.

I'll try to get it tuned soon to see how much can be extracted from it, but for now, it's already a very fast 986 !

I might make one modification to the plenum, to keep the stock AOS tube.

What do you guys think ? Keep the sotck AOS tube with quick fittings, or replace it with a longer lasting, cheaper to replace but not as clean looking silicone hose ?

I like the silicone hose for it strength, but it doesn't look as clean as the stock installation with the plastic hose and Y fitting.


Ben.

I have to start by saying great work! But you already know that. I personally prefer the look of the stock connections and corrugated tubing. For me, the hose clamps detract from the look. I guess it ultimately depends on the complexity and cost of making it connect to the stock fittings. After all, who really sees this part of the car anyway.

By the way, I assume the design does not incoporate a “splitter” to separate the air flow to both intakes. First, would you even recommend doing something like that. And second, if so, how would you recommend attaching a splitter?

Ready in March I hope?

I suggest making it most likely to pass the visual Inspection for Smog Test.Yes, I know it is unlikely the average Smog Tech would know what to look for but if you ever had to go to a Referee it may be an issue.
"I might make one modification to the plenum, to keep the stock AOS tube.

What do you guys think ? Keep the sotck AOS tube with quick fittings, or replace it with a longer lasting, cheaper to replace but not as clean looking silicone hose ?

I like the silicone hose for it strength, but it doesn't look as clean as the stock installation with the plastic hose and Y fitting."

What do you guys think ? Keep the sotck AOS tube with quick fittings, or replace it with a longer lasting, cheaper to replace but not as clean looking silicone hose ?

Keep the stock AOS

I see there is no price on your website Ben, any idea how much and when?

I’ll try the silicone hose with spring clamps instead of hose clamps, that way it will look cleaner.
The first batch will be with silicone hose until I test the other solution ;)

They should be available early March, for around 450€ with the complete intake tube !
It’ll be almost a drop-in kit !

Ben.

Two words...
 

Dyno Results

Look forward to that, currently working on exhaust and now broke so timing may be good.

Two more : Smog Test.
If this mod or some boy-racer stickers get you sent to the Referee .......
Let's try to fly under the Smog radar?
Helping the AOS and SAI issues would be a great bonus.

No dyno results...

Two reasons :
-It's quite hard to find a dyno around here
-I don't have enough time to conduct such a test... it already took me weeks to find the time to fit it on my Boxster !

Though, I bet you won't need a dyno to feel a difference. It's big enough to be felt by anyone, even without a tune. ;)

I understand that for some, this is not enough... so I bought a complete 986 intake system, and I'll do a comparison of the pressure drop across it with the stock plenum/TB, and the carbon plenum + big TB.

We'll see if I can show significant results this way or if I just bought some expensive wall decoration ahah.


Ben

Looks great, but could you clarify if you used the 83mm or 74mm throttle body in the final application. I read back and I know you started out with 74mm. Thanks.

Two reasons :
The 83mm TB is huge, and is hard to fit underneath the 986 cover. And requires more than just the plenum to fit, which would make the kit more expensive.
With the stock airbox, it becomes a limiting factor way before the 74mm TB, so unless one fits a 987 airbox, it's not justified to pay extra for nothing more.

Soooo, I'm a bit late on schedule ... But they are finally DONE !
Yes !
https://i53.servimg.com/u/f53/13/27/76/86/img_7423.jpg
https://i53.servimg.com/u/f53/13/27/76/86/img_7424.jpg

The glue is curing, one last sanding inside, and DONE, just have to pack them and ship !
I'll contact all of you that have contacted me for one.
I'll take care of selling the first batch, so if you want one -> PM ;)

If you want to hear how it sounds :
<iframe src="https://www.facebook.com/plugins/video.php?href=https%3A%2F%2Fwww.facebook.com%2FBe nAutoDesign%2Fvideos%2F1977221335906320%2F&show_te xt=0&width=560" width="560" height="315" style="border:none;overflow:hidden" scrolling="no" frameborder="0" allowTransparency="true" allowFullScreen="true"></iframe>
It's mostly intake noise, stock muffler !


Ben

Here is the complete kit :
https://i53.servimg.com/u/f53/13/27/76/86/img_e710.jpg

8 left ;)



Ben