Intake/Exhaust Upgrades for a 2003 3.2 S

[KRAM36]

Originally Posted by drumboxer

Hey everybody, I am new to the forum and new to my Boxster S (had a '99 previously and loved it). I have been reading feverishly through posts about upgrading intake and exhaust to get more power out of my 3.2. This is primarily a street car, but will be used at the track 3-4 times a year. I also have several other mods going on (RSS pulley, deep sump, IMS, safety bits, etc.), but am really just focused on intake/exhaust at the moment.

The list of parts I am starting with is here, and I have a few questions:

- OEM 996 76mm Throttle Body only, and USE a 997 Distribution T to your stock Plenums
- OEM 987 Air Box, MAF, and Filter You will need to push a tune from a 996 of the same year as your car using the 987 MAF housing.
- Aftermarket Headers, Test Pipes, and Muffler/Exhaust

Questions:

1) I have read some posts where users said they needed to use a 987 Cayman engine cover in order to get clearance. Other users said you can simply cut the "muffler" off of the 987 air box in order to make it fit in a 986. My question is, with the intake set-up above, what will I need to do to make it fit? No need for the engine cover as long as you stay with your stock plenums.

2) I have seen posts with positive reviews of exhaust parts from both TopSpeed and Manzo (M2). Both are inexpensive (and therefore appealing) options next to the big names at Fabspeed, etc. I have noticed that the header+testpipe+muffler combo from TopSpeed is now nearly double the price ($1200 vs. $600) of the same set-up from Manzo (both are on ebay). Is anybody familiar enough with both set-ups to talk about the difference? What am I getting for the extra $$$ at TopSpeed? Get Circuit Werks cat delete pipes they are the best. Currently out of stock is why the price is so high. They are normally $189.99 Circuit Werks Porsche Boxster 986 00 04 2 7 3 2 Test Pipe Cat Delete Testpipe TP | eBay My pick on the muffler would be Borla Borla Exhaust System for 00 04 Porsche Boxster s Boxster Roadster s 3 2L 140115 | eBay

3) Lastly, what do you recommend for tuning the ECU once this modification is done? I am used to playing with much older cars, and am completely unfamiliar with this process. I have seen several places that ask you to list out your mods and send your ECU in by mail, others that offer a tuned product you can buy, etc. Any recommendations? I am located in Indianapolis, IN, btw, in case there is someone you know of locally. You will need to push a tune from a 996 of the same year as your car using the 987 MAF housing.

THANK YOU!!!

Modified in your quote.

Another good move. Get these clamps to connect the Circuit Werks cat delete pipes to the Borla muffler. http://www.verociousmotorsports.com/Shop-by-Brand/Torca/EasySeal-Exhaust-Clamp-Stainless-Steel

Borla exhaust

[tommy583]

Originally Posted by KRAM36

Modified in your quote.

Another good move. Get these clamps to connect the Circuit Werks cat delete pipes to the Borla muffler. EasySeal Exhaust Clamps: Torca EasySeal Clamps in Stainless Steel for Lap Joint Connections

Borla exhaust

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[edc]

If you are doing the larger throttle body then you will need a different airbox to TB intake. I made one up along these lines http://www.boxa.net/forum/index.php?showtopic=53075&page=9#entry685186

[KRAM36]

Originally Posted by edc

If you are doing the larger throttle body then you will need a different airbox to TB intake. I made one up along these lines http://www.boxa.net/forum/index.php?showtopic=53075&page=9#entry685186

I'm running the stock 986 MAF housing and using the stock 986 piping to the 76mm TB as I don't want to do a tune on my car just yet.

Pics will be coming soon.

Once I get the headers, cat delete pipes and Borla muffler, then the tune will come along with using the larger 987 MAF housing and larger piping to the TB.

[edc]

The standard intake pipe that fits over the 68mm TB won't fit over the 75mm TB so you will need to get creative.

Edit - not only that but when you mate to the 996 plenum T the shapes are different so the TB points in the wrong way to use the standard intake piping.

[KRAM36]

Originally Posted by edc

The standard intake pipe that fits over the 68mm TB won't fit over the 75mm TB so you will need to get creative.

Correct, however the OD of the part that goes over the TB is 80mm which is the same size as the OD of the 76mm TB. So you just have to use a 80mm ID silicone tube to connect them. I've also reenforced the thin wall of the stock pipe.

[KRAM36]

Originally Posted by edc

The standard intake pipe that fits over the 68mm TB won't fit over the 75mm TB so you will need to get creative.

Edit - not only that but when you mate to the 996 plenum T the shapes are different so the TB points in the wrong way to use the standard intake piping.

To your edit. I'm using a 997 Distribution T and yes they do not mach up. That is where you use a 90° 80mm silicone tube.

http://www.ebay.com/itm/Racing-Silicone-Hose-Elbow-Coupler-Pipe-3-15-to-3-15-90-Degree-ID-80-mm-Black-/141439976411?pt=Motors_Car_Truck_Parts_Accessories&hash=item20ee7ac3db&vxp=mtr