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-   -   BoxsterLS376 introduction - LS3 conversion :) (http://986forum.com/forums/showthread.php?t=54328)

JRL 11-20-2014 01:53 PM

Here is a link to the Cayman build

Porsche Cayman + LS3 - LS1TECH

Boxster 50 11-20-2014 04:29 PM

JRL
Thanks for the info. I only found a couple pics..... I like the sub frame/engine mount they built.

Qmulus 11-20-2014 07:36 PM

Interesting, but I don't see how they will plumb the coolant lines or install any kind of firewall between the engine and the interior using the stock LSx water pump. The fabrication of the brackets, etc. is nice, but the packaging needs some work. You can take a few inches off of the front of the engine making room for the firewall by using a remote electric water pump and the LS4 crank pulley, and still have room on the sides of the engine for the accessories.

BoxsterLS376 11-22-2014 12:31 PM

Quote:

Originally Posted by Boxster 50 (Post 425731)
LS376
Wow!! Looks like you are going to have to experiment with things. The rubber mount looks fairly simple. Maybe they just forgot to pack it with the kit. :) I hope the rear mount fits because of how wide it is and I like the lateral support that it gives. I would think it will fit because that is what will realign the axles front to rear?? Not sure about the angle. On the bright side it looks as if you have some room around and under the exhaust manifold for the exhaust system. Will you custom built your exhaust or does Renegade have something built ?? Sorry for all the questions.... I am just excited for you. I wish I lived a bit closer so I could come by and help ya out. Last question for now.. What is your time line??

Quote:

Originally Posted by Boxster 50 (Post 425734)
LS376 No sure if you checked this sight out or not but it looks interesting. engineswapdepot.com It is a LS going into a Cayman. Looks to be home grown.

I hope they forgot it but somehow I doubt it! The axles/transmission pretty much line themselves up, it the mount if bad wrong then you won't even be able to get the axles into place. I'm sure the axles are going to be the weak link in the system so hopefully the Renegade boys come up with a better solution, either that or i'll take some axles up to Indy - those guys can make anything up there :D

The exhaust should be fun and yes I plan to build it myself! The LS system comes with O2 sensors so those will have to be welded into place but I would also like to add some small catalytic converters to make sure it is smog compliant. I must say I like one system they did in particular with a pair of Magnaflow mufflers and may just copy the design... :)

I have not checked out that build yet but will indeed, thanks!

I made a bit more progress yesterday although the pictures are still on my phone and I'm feeling lazy so i'll post them later. Most of the cutting on the mid-lower section of the firewall is done and cleaned up. Just need to notch out the top of the firewall which I may wait until the motor/transmission are bolted together to do a bit of test fitting rather then just cutting by looking at pictures!

BoxsterLS376 11-22-2014 12:39 PM

Quote:

Originally Posted by JRL (Post 425743)
Here is a link to the Cayman build

Porsche Cayman + LS3 - LS1TECH

Thanks!

Quote:

Originally Posted by Qmulus (Post 425776)
Interesting, but I don't see how they will plumb the coolant lines or install any kind of firewall between the engine and the interior using the stock LSx water pump. The fabrication of the brackets, etc. is nice, but the packaging needs some work. You can take a few inches off of the front of the engine making room for the firewall by using a remote electric water pump and the LS4 crank pulley, and still have room on the sides of the engine for the accessories.

+1 - That is some very nice fab work but probably hasn't updated the thread in months trying to figure out the plumbing in that thing! Definitely not shy about cutting it up that's for sure!

unibagel 11-22-2014 03:44 PM

I'm curious to follow this build and can't wait to see the results! Keep us posted!

BoxsterLS376 11-26-2014 11:51 AM

Pre-holiday update~
 
Good afternoon everyone!

Got a bit more done over the last few days, including some time spent at work on it... did I mention that I have the coolest boss ever?!?! :D

I have done all of the cutting I am going to do until I can test fit the motor into place, but all of the major cutting is done, the rest is more trim/fit work. It is prepped to have the weld in cross brace put into place which I hope to get done over the holiday weekend.

In the mean time we went ahead and began to test fit the cradle into the chassis to see how it is all going to go together. Unfortunatly that can't really be done until some more parts arrive as I had another chat with Renegade and it seems their pictures include more then what actually comes with the kit :/

So... I figured I would go ahead and throw a check list out here just so you all have an idea of extra parts that are required which I could not buy from Renegade... Some I was already aware of, some I was not, but either way here is a list thus far, i'm sure it will grow anyway so in no particular order here goes...

1. New transmission mounts - factory mounts inadequate and don't really fit with the kit.
2. Motor mounts, 2 parts - neither the new crate engine, nor the kit comes with them. Need to source aluminum Corvette motor mounts to attach to the block, plus urethane mounts to attach aluminum mounts to cradle.
3. LS4 harmonic balancer - LS3 motor comes with a dual pulley setup, this shortens it to a single setup.
4. Corvette oil pan - Not 100% sure on this but Steve @ Renegade said it allows for more clearance. Once I get some mounts to bolt it together with i'll see.
5. Inline thermostat for cooling system - When you take off the LS3 water pump the t-stat is a part of it which goes away when you install the Renegade water manifold, thus unless it is a racecar you probably want to have it.
6. Breather plate modification for intake manifold - Necessary to turn intake manifold around 180*. If you are a handy TIG welder and have a good metal saw you can do this yourself. I could attempt it but would rather have someone who TIG's day in and day out handle it as to not ruin a perfectly good breather plate!
7. Exhaust system - pick your poison on this one. I'm going to build it myself, will likely get headers, small cats, mufflers. Plus you need to weld in the o2 sensor bungs for the GM ECU.
8. Engine oil cooler - not necessary, but recommended. They show it tucked in nicely by the passenger side intake.
9. Some angle iron to attach power steering pump to car - P/S pump comes with a nice custom bracket but no way to actually attach it to the car, Steve said all you need is some angle iron... hrm, would have been nice to have something fabbed up with the kit though :/


Well time to get back to work, here is a bit of the final cuts, plus a few with the cradle bolted up...
Thanks!
J

http://986forum.com/forums/uploads01/11417032556.jpg
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BoxsterLS376 11-26-2014 11:54 AM

Cradle pics...
http://986forum.com/forums/uploads01/61417035171.jpg
http://986forum.com/forums/uploads01/71417035201.jpg
http://986forum.com/forums/uploads01/81417035240.jpg
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BoxsterLS376 11-28-2014 01:41 PM

Bit more done today
 
http://986forum.com/forums/uploads01...1417214464.jpg

Pdwight 11-28-2014 01:56 PM

Wow
 
A Bay window ;)

Looks like you really got a handle on this now.

JRL 11-28-2014 02:25 PM

Looking good John. I going to try to drop by Monday if that works for you

R

BoxsterLS376 11-28-2014 06:47 PM

Yeah things are moving along pretty good now! I got the urethane motor mounts today and just ordered some used C6 corvette mounts from Ebay so hopefully they will be here by next weekend so we can do some test fitting.

Got some better pictures of the steering setup so I'm going to try and get that started this weekend too.

Randy, feel free to drop by anytime!
Thanks!
J

Pdwight 11-28-2014 07:52 PM

Im curious how the exhaust will be handled

BoxsterLS376 11-29-2014 03:39 AM

Quote:

Originally Posted by Pdwight (Post 426629)
Im curious how the exhaust will be handled

Here is a sneak peak of how Renegade did their exhaust on the LS7 car....
http://986forum.com/forums/uploads01...1417264738.jpg

jaykay 11-29-2014 08:02 AM

I think there is a way to route a V8s exhaust such that the classic V8 lumpy sound is changed to sound like a flat plane V8. I believe it involves crossing of bank flow like you have in this picture to smooth the exhaust pulses. Might be an option if you want it to sound more exotic

JRL 11-29-2014 08:16 AM

Quote:

Originally Posted by jaykay (Post 426651)
I think there is a way to route a V8s exhaust such that the classic V8 lumpy sound is changed to sound like a flat plane V8. I believe it involves crossing of bank flow like you have in this picture to smooth the exhaust pulses. Might be an option if you want it to sound more exotic

I think you may be thinking about 180 degree headers (bundle of snakes like a GT 40 and most older Can Am cars) but I may be wrong. Maybe someone can chime in.

I'm thinking I will try to use a Boxster type muffler plumbed to the stock LS headers. I don't want a really loud exhaust - I want to retain a sleeper sound to the untrained.

BoxsterLS376 11-29-2014 01:02 PM

Been thinking of doing it with some electric turndowns so I can have a Jekyll/Hyde option :D We will see!

Got a bit more done today... Finished fabricating the cross mount and e-brake mount area. Definitely didn't like the little tabs they had so I just made a piece to go across the top of the ebrake. I'm not sure if i'll need to run anything through the top of the tunnel so I left a bit of space in case it needs to be cut up, if not then in the future i'll close up the whole top of the tunnel but this works for now. I went ahead and welded the nuts onto the back of the mounts so all you need is a 10mm to pop the 4 bolts out like the factory setup.

I also started getting the new electric power steering setup installed. Got the holes cut in the fender well and fitted with grommets. Lines route pretty nicely to the steering rack, almost wonder why Porsche didn't go this route...? Hopefully it doesn't steer like ass :eek: I need to get a set of O-rings for the steering rack lines but otherwise the stuff on the bottom is done. Now I just need to figure out how to mount the pump itself and get power to it! I'll take more pictures when I'm done but I included one with the holes drilled and lines routed through before I put the grommets in so you can get an idea of how it goes...
Enjoy!
J

http://986forum.com/forums/uploads01...1417297479.jpg
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Boxster 50 11-30-2014 10:01 AM

Looks like you have got a lot done!! Gone on a cruise for Thanksgiving. Fun times!! I like the improvement that you made on the E brake mount. Much better then the tabs. Sounds smart to wait to see if you need access to the tunnel before you close yourself off with a plate. Did you figure out what you are going to build for the trans mount ??? It sounds as if renegade left you hanging once again. :mad: Thanks again for the updates and the pics !!! Good luck on the test fit.

BoxsterLS376 12-01-2014 02:37 AM

Quote:

Originally Posted by Boxster 50 (Post 426796)
Looks like you have got a lot done!! Gone on a cruise for Thanksgiving. Fun times!! I like the improvement that you made on the E brake mount. Much better then the tabs. Sounds smart to wait to see if you need access to the tunnel before you close yourself off with a plate. Did you figure out what you are going to build for the trans mount ??? It sounds as if renegade left you hanging once again. :mad: Thanks again for the updates and the pics !!! Good luck on the test fit.

Thanks 50,

I wouldn't say they left me hangin'... all it took was a phone call to find out I needed to buy more stuff! The rear mounts they use are WEVO boxster mounts... apparently they even have a "special" version for the Renegade V8 conversion which is apparently not that special, but has a Renegade part number or something on it... Would have been nice to know that before so I could have had it over the long weekend... Oh well maybe next weekend~

Smallblock454 12-01-2014 06:39 AM

Great project! :cheers: Subscribed.


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