When this project is all done, it would be very helpful if you would post a list of all the parts required since Renegade's list is not complete.

Thanks for taking the time to take and post all the pix. Makes a big difference to visualize the process vs. just reading about it.

axle geometry
 

The renegade exhaust looks great. However from the photo it looks like the axles are a bit on a rearward angle. Can you give guess as to how different the axle geometry to the transaxle is off compared to stock? Both horizontal and vertical. Probably difficult now as you're way into it and haven't done a trial fit. My 993 is notorious for eating rear tires and my guess is the boxster ls will too. Did Renegade give you any info on the geometry and how to do a rear end alignment? If anything is different because of the axle geometry.
Can't wait 'til you finish this as I'm seriously interested in doing this or having this done. We may all be in line at your Georgia shop when your done. Thanks for taking us along on your work!

Got a bit of a list going and will try to keep it updated for you all... so far you are looking at $1500+ worth of additional expenses but i'll tally it all up for you when i'm done!

Thanks bc993!

I don't have an exact figure yet but that is definitely going to be the weak point in the system I think. I believe it locates the axles about an inch or so further back which is going to cause a bit more stress the stock, especially with the added power. Renegade told me a guy wore out a set ox axles in about 6 months with track use, and they are currently trying to source an upgraded solution. The good news is there are cheap axles available out there if you know where to look so i'm not to worried about it for now. I expect things will break but will cross that bridge once we get there. Hopefully the alignment wont be a big deal but never know~

Got the last of my motor/trans mounts yesterday so I should be able to do a bit more mocking up this weekend if time allows. Just need to make sure the Camaro oil pan on the LS3 is going to give sufficent ground clearance or if i'm going to have to swap it for a Corvette one... fun stuff!

Thanks!
J

Paid John a second visit today - he is - friendly - knowledgeable - helpful and does very good work. His attention to detail is off the charts - a real thinker.

If any of you guys are serious about doing one of these cars you need to talk to him and schedule a visit.

Thank you for the kind words Randy!

Ran into an interesting problem last night after you left the shop. I went to install the "LS4" harmonic balancer and everything seemed to fit right so that is good... but when I went to put the old balancer in the box I noticed a little gasket/seal popped off of it which the new one did not have...This not good.

Sooo off with the new harmonic to investigate, figured just swap the gasket onto the new harmonic... yeah, nope not that easy. As it turns out the back of the new LS4 harmonic is just slightly larger then the one from the crate motor and doesn't quite fit right, I'm sure it would work better then having nothing but I want it to be right so another call to the parts store... We've got friends at the local Cadillac dealership which is who provided the new balancer for me so I called them up and ordered what I assumed to be the right piece which had to be ordered and would be in Saturday morning. Great.

So Saturday afternoon and I go to the dealership and sitting on the counter is my seal, just not the right one, they special ordered a front main seal for me :( Not the right piece. So we start running through the parts diagrams and ran into an issue, apparently the 5.3 LS motors do not have this seal, which is apparently called a harmonic balancer washer, even though it is a flat metal seal with rubber attached but whatever, bottom line is no solution from the dealer.

So now unless someone on here can chime in with some advice looks like i'll be calling Renegade again on Monday to see what the proper solution for this is. I'll likely get an answer like "just use the one from the old balancer" or "just leave it out"... Hopefully there is a good solution as I'd rather not have a brand new motor with an oil leak!!

Here are a few pics... anyone with info feel free to chime in~

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Well a bit more something today, although I wouldn't call it progress~ No response from Renegade yet...

So far it looks like the washer is probably not that big of a deal, but what does seem to be a big deal is that the new balancer is not quite long enough to bottom out on the oil pump :/ Shorter by about 3/16th's of an inch so looks like i'll have to add a spacer in between the crankshaft and the harmonic balancer... Would have been nice to know. Oh well more delays~

Other news is that the oil pan is most definitely not going to work. It fits, but ground clearance is the issue. My boss and I jumped in the back today to mimic the motor/trans although short by about 400 pounds! At best with no suspension travel there is only about 5 inches of clearance with the current oil pan and in reality probably less then that once everything is in the car so add in suspension travel and the damn thing will be bouncing about 2 inches off the ground... no bueno~

Luckily there is a factory type solution for this in the forum of the Corvette oil pan which is only about 5 inches tall vs. 7 inches for the current pan so there it is. If you are building a track only car then you will probably be OK, if you plan to drive it on the street and don't want to rip your oil pan off on a speed bump, better replace it...
12624617 PAN

So I take it seal is a slight press fit on the harmonic balancer? Seems to me that if you need a spacer, you would machine up a ring of steel to accept the seal on the crank side and press over the harmonic balancer on the other. Is that seal notched for a Woodruff key?

Hey Qmulus,

There are no woodruff keys on the crank, everything is just a press fit~

I did recieve an email back from Steve @ Renegade last night and it seems the kit does come with the appropriate spacer for the balancer... Unfortunatly I can't seem to find it right now and will have to get another one made.

The seal it seems is not necessary according to them so to heck with it! Now if I can only find that damn spacer!!! :mad:

J

a spacer
 

I mean if I were Renegade I would send a customer one gratis. ....they could have left it out.

Wow.... The more I follow the more I think I will wait for the Ls376 kit. Other then the adapter for the trans it sounds and looks like you could have done this swap on your own. No doubt Renegade has saved you some time but the kit just doesn't look like it is worth the money. All these little nickle and dime things add up and down time sucks! Best of Luck and I admire your attitude!

What is the Ls376 kit you reference?

+1 Who, what and where ?

Hi,

maybe he means the Renegade conversion kit. Tried to make a reference to the Boxster conversion kit description on the Renegade website, but that didn't work. So i've made some screenshots an put them together.

http://986forum.com/forums/uploads01...1418565958.gif

Regards from germany
Markus

Smallblock454, bc993 and JRL I was just giving props to Boxster(LS376) by saying I would just wait on his kit because he has been doing a better job then Renegade with the details of the build. I guess it didn't come off the way I intended. :D

No problem - I was just confused as John is using the Renegade kit and to my knowledge Renegade is the only kit and I'm not aware of any other kits coming out in the near future.

Yes, it was a bit confusing. However I couldn't agree more as Boxster(LS376) does indeed deserve the props. In addition, one would think Renegade would be following this thread closely and actually supplying more Tech Support if their intent is providing quote a "Kit". What Boxster(LS376) has gone thru so far does not constitute a kit in my opinion.

I'd be more compelled to work with Boxster(LS376). My guess he with the help of his boss might even fabricate better solutions where Renegade is lacking.

Back in July there was this thread as well but with an Audi transplant. I also had interest in this solution but no new info on that thread.

http://986forum.com/forums/general-discussions/53095-boxster-v8.html

Hey everyone,

Sorry for the lack of updates lately but now I finally have some news to share... The bummer is I just spent 30 minutes typing stuff up only to have Internet Explorer crash on me - YAY! So here is the short version of what has been happening...

Finally for my breather plate back this week so I can get the intake in place... still have to make a few mods but nothing major. For now I'm just going to get an aftermarket oil pressure gauge but I have heard of a 996 Carrera instrument cluster swap which I may try in the future...

Finally got my oil pan... FYI don't order one from Marine Engine Depot, they are cheap but they don't actually have them so after waiting 2 weeks I called and cancelled cause they won't have more until mid-January...

Luckily a guy down the street who does RX7 V8 conversions have exactly what I needed so we are rocking and rolling again... hoping to test fit the motor this weekend!!!

I'll update with pics in a few days!
Thanks!
John

Probably wasn't IE's fault probably would have occurred in any browser, have had that happen to me numerous times on this and other forums. Most likely your session timed out. Just FYI if you're going to write/type a lot of info ... compose it in Notepad or some other editor first. Then cut and paste into the thread. Learned this early on as I can't type for S&%T.

interesting would like to see photos if possible

She's home~
 

Merry Christmas everyone! Happy New Year etc. etc. etc.~

Hope everyone had a great holiday, I finally made a bit more progress this week and finally got the Chevy motor to fit into the Boxster chassis! Still a lot of work to be done but definitely reached a milestone~

Oh but it was not without its trials and tribulations ;) When I went to put it in the first time I still had some trimming to do so I basically got the front of the motor about where it needed to be and figured out what I needed to cut... done and done! Well upon my second attempt I got the two front bolts lined up, but the rear was nowhere close, I mean like 4 inches off. SHIZA!!

Took it back down and tried to figure out what happened. Went to look through my "instructional pictures" Renegade sent me and first picture I found discouraged me quite a bit. Actually it made me feel downright stupid and made me want to give up on the whole project :( Looks like I had put the motor mounts on the motor backwards :confused: Not a happy camper :mad:

Well after shouting a string of obscenities better then the kid from A Christmas Story I calmed down a bit and started looking at it all again... Let me present to you exhibit "A"...

http://986forum.com/forums/uploads01...1419624710.jpg


Well at that point I figured out pretty quickly what happened... It may be hard to tell but in these two pictures I was sent the freaking mounts are on in different configurations?!?!?$!?#$@!$#@! I was still pissed, but at least I felt better about it not being my fault!! I'm sure there is some reason for it, LS1 motor vs LS7 but come the F on man. Oh well.

So after some re-rigging of the mounts I figured out where things were supposed to live. Third attempt going in and BANG!! LIKE A GLOVE!! Almost as if it was put there by the factory! I didn't bother putting in the center cradle as it all has to come back out but it sure felt good having it all come together overall fairly smoothly.

I must give credit to the engineering of the kit, it is tight but fits right in!

I made a few videos, the short one is done but the longer version will take a bit longer, here's a link to the shortie: http://youtu.be/g9Um4PM9tz4

Here are a few pictures of it tucked in... i'll be back later with the other video!!
THANKS!!
J
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Wow tight isn't the word.

Looks like paper thin clearance on the oil pan.

Nice job.

I need to drop by the shop next week - let me know what works

R

CLU needed?
 

My CLU (Immobilizer) and my 3.2L are both toast on my 01 Box S so looking at the LS. I think I read the conversion uses both the Chevy and the German ECUs but is the Immobilizer also needed?

I shipped a complete 3.2 on a pallet and it weighed 420lbs. Great build thread and I'm shocked we haven't had any haters say anything yet.

Thanks for the info.

Based on that I'd guess the conversion will add 200 - 300 pounds possibly a little more. Still a good trade off as you are just about doubling the HP.

I think the stock Boxster S is carrying about 11- 12 pounds per HP - the converted car should be in the 6 - 7 pound per HP range all things being equal. :)

Thanks, hopefully the haters stay away, this build is definitely not for the purist! You will probably have to weigh everything individually to know the exact number... i'll just weigh the car after I'm done, which will be done on corner balancing scales~

All told probably 250-300 is a good guess as the LS3 motor is right at 500 lbs itself... add the kit and I can definitely see about +300~ or so.

I LIKE THIS VERY MUCH :D

My internet has been giving me crap the last 2 days so I am re-uploading the longer version video I made and hopefully it will work this time. If so it will be available here in about 2 hours or so - http://youtu.be/ixPZD731alM

I made 2 more quick videos today which i'll try and upload as well. Pulled the motor back out and put the intake manifold on, tried to tuck it in and not enough room so I pulled it back out and got the cutting saw out again. I trimmed away all the excess metal underneath the center lock latch for the engine cover and it got me another half inch or so but more room is still needed.

I also went ahead and trimmed up the back of the compartment to make room for the throttle body and MAF stuffs. There is not really as much structure back there as I thought, just pulled the foam out of the way and basically made 3 cuts and whacked a large area off to make sure I have plenty of room. i'll post the videos after this long one finishes

Thanks!
J

With the extra weight in the middle, it should have less negative effect than if it was in the front or back. I know a guy locally that's sticking an iron block 6.0 in his boxster. He also plans on throwing some turbos on it!!.:eek:

First video from today is ready, you can check it out here~ http://youtu.be/GgzC2a4_Nb0
Thanks
J

I'll grab this one. Yes, you still will need your immobilizer unit. It also controls the top, windows, locks, etc., so you will still need to have that module functional.

Dang .. I was really excited at the propect of an LS3 motor in my car when my stocker goes .. but at $30k all in from Renegade, "DIY'in" this huge undertaking with little support from the "kit" manufacturer, or have a shop tackle it at $100 / hr. Personally, I don't see a good option out of those 3. Mad respect that you're able to do it.

Thanks man,

It is definitely a big undertaking but to make it less intimidating just look at it one little step at a time and it has not been that bad. I'm going to try and highlight all the difficult areas here so everyone understands what they are getting into.

Reality is that if you already have a car to use, have the time and patience for a project like this and are willing to take on the project yourself, it can be done for right about $20,000 which is definitely a bargain for what you are getting!


Got the last video of the weekend uploaded this morning, should be available shortly~
http://youtu.be/f44Lh86yric


Anywho back to the daily grind :D Maybe i'll get some more work done on the car today :p

Thanks everyone!
J

Greetings all.

Hope everyone is having a better new year then me so far! Sooo been making good progress doing final fitment for the motor etc. and decided that the valve covers needed to be swapped around to have better access to the oil fill...
Well in pulling off the passenger side valve cover I found a HUGE chunk of aluminum in the cylinder head. It not Eiffel Tower huge - but for being inside of a brand new motor it is pretty damn big... I've already talked to Chevy and sent them an email which you can see here that better explains the entire situation:
-------------------------------
Hello Travis,
Thanks for looking into this situation for me. Here is a quick overview of the situation so you can pass it along to whoever needs the info...
When the motor first arrived the oil filler cap was not on the motor and I assumed that someone had simply taken it, but it was later found down in the bottom of the crate. It appeared to have been knocked off but still works so I didn't think much of it. Today I was in the process of switching the valve covers to make oil fill easier in this project car. When I took off the passenger side valve cover, almost directly below the oil fill spout(see pointing picture) I found a small piece of broken plastic which I believe to be the lock from the oil filler tube, but then also found a large piece of broken aluminum which I have pictured below. It is about 1/4" wide, about 1/2" long and about 1-2mm thick. Beveled/machined on one side, broken on the other with signs of blue valve spring paint on it.
I have thoroughly examined both cylinder heads and can not see any place where this piece could have broken off of, there appears to be no damage at all.
Please pass this information along to your technical department and if there is anything I need to do by way of additional pictures/videos or information just let me know.
--------------------------------------------------

They have been very responsive and are awaiting more pictures and info from me, but right now this is a big bummer as I may have to send the motor back to Chevy and have them go through it to make sure everything is OK. This my friends is a prime example of why I decided to purchase a new crate motor vs. a used motor. I would be SOL with a junk yard motor, but instead it's going to be taken care of - a lot to be said for buying new with a warranty!!!


Well that took the wind out of my sails until I find out what needs to happen with the motor. In the mean time I went ahead and got the electric power steering pump mounts fabricated and I think it's gonna work. I'll get some more pictures and try to put a quick video together on it this week.


Thanks
J

Pictures of offending metal chunk~
 

My best guess is that it is a piece of valve cover broken off when the oil fill was knocked off. I think the valve cover was replaced but the broken piece was not recovered... at least that is what I am hoping~ :/

http://986forum.com/forums/uploads01...1420315751.jpg
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Hang in there because it will be worth it. I just spent New Years Day carving canyons with Scott Mann of Renegade in his LS Boxster. That thing is a monster that looks bone stock. All the 930 Turbo guys were suitably annoyed as you might imagine.

Awesome build! I'm very tempted to try to do this myself. Can't use a crate engine and pass smog in California though. You have to use an engine pulled from a newer car. Looks like the stock Corvette cats would fit since they are so close to the exhaust manifolds.

I wonder if it would be possible to use the LS4 water pump and accessory layout? It was mentioned in the Cayman + LS3 thread on LS1tech. Might be able to avoid having to use an electric water and power steering pumps. Looks like the alternator position would be a problem.

http://986forum.com/forums/uploads01...1420333052.jpg

Bummer about the engine. At least you caught it before you fired it up.

Thanks everyone!

Well good news - ish~ After sending pictures and videos to Chevy I just spoke with them and they advised to proceed with installation. We are 99.9% sure that the chunk is from a broken valve cover filler spout. The oil filler was clearly knocked off at some point and the valve cover broken and replaced, but obviously the broken wasn't recovered until now.

They did give me the option to go ahead and send it back to them but it would require putting the motor back to stock configuration. Even if there is a problem it is under warranty so I can send it in later, plus I they mentioned that the warranty may also cover part or all of the removal & reinstallation of the new motor. So it would definitely suck if there is a problem but I think we will be ok.

sooo BACK TO WORK! :D
J

Can we be friends? Haha seriously, I am doing the same thing I have my kit and I'm getting ready to get this going but lack of instructions and "lots of pictures" is killing me.

Greetings my friend - of course!! I totally feel your pain which is why I've been trying to document this as much as possible. To show people the ups and downs of the project and try to make it easier for the next guy.

I feel pretty damn comfortable at this point and feel like I'm actually getting closer to the finish line as things are really starting to come together. Only a few more blind corners ahead and hopefully this baby will be making heat before the weather does!!


So after finding that hunk of metal in the top of the motor after changing the valve covers around I got the top of the motor back together with the intake on. Make sure you clearance the intake as there are a few bits that hit which will keep it from seating properly. It is pretty easy to cut out what you don't need with a small dremel tool or even a sharp razor blade. I'll put together a better video and show all those bits soon.

Car was buried in the shop so instead of trying to get the motor back in I decided to play with the wiring a little which all seems very straight forward, again I'll put together a more detailed video later this week!

Here is a quick video for those who are interested~
http://youtu.be/dlLVfMJD-vc
A few pictures below... including a very appropriate fortune cookie this week!!!
Thanks!
J
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Thanks so much, I will definitely take all and any advice for this if you are willing to lend a hand. I am in the middle of rebuilding my motor and once we get to it I am sure I will have some questions. Thanks man!!:cheers:

BTW in case you didn't find out yet the OEM part for the engine cover I'm 90% sure it's was the OEM TOP engine cover for a 987, they just pounded it down to shape. It's about 1-200 bucks online. They said it even matches up to some bolt holes!

I bought 2000 s now saving my money to start . THanks for your pics and directions at least I know that my build will have some help.

You are welcome and good luck! I'll check into that cover once we get this bad boy moving on its own!! :D

You are very welcome too! PM replied to~ I think that everyone should have a V8 Boxster so just let me know if I can help!

1.18.15 Update -

Greetings all,

Been a crazy week so not much progress, I wanted to get the motor test fit this weekend but we got unusually busy at the shop this week so it may have to wait. Finally had some time to get the wiring onto the motor and sorted a bit better. Since the intake manifold got swapped backwards there are some critical bits of the wiring harness that no longer reach where they need. Luckily Chevy decided to use a split loom for the harness so after lots of removal of electrical tape I was able to get the wires where they needed to be. Also when you are taping it back up - THIS IS NOT THE TIME FOR CHEAP ELECTRICAL TAPE!! Go out and buy some good Scotch/3M tape and you will be much happier with the results!

Also got my harmonic balancer space from Renegade which they ended up sending at no additional cost - YAY!!! THANKS RENEGADE!!! :D

Did a few quick videos on the wiring, here is the first and a second is on its way:
http://youtu.be/OZzcvV3ngeI
http://youtu.be/PdM4idlNjrM

Plus a few pics including part of the reason I can't get to the car so easily - had a true "barn find" dropped off on us yesterday - a bahama yellow 1970 911T!

Thanks!
John
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