BoxsterLS376 introduction - LS3 conversion :)

[BoxsterLS376]

Cradle pics...

[BoxsterLS376]

[Pdwight]

A Bay window

Looks like you really got a handle on this now.

[JRL]

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

R

[Pdwight]

Im curious how the exhaust will be handled

[BoxsterLS376]

Originally Posted by Pdwight

Im curious how the exhaust will be handled

Here is a sneak peak of how Renegade did their exhaust on the LS7 car....

[jaykay]

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]

Originally Posted by jaykay

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.

[bc993]

Originally Posted by BoxsterLS376

Here is a sneak peak of how Renegade did their exhaust on the LS7 car....

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!

[BoxsterLS376]

Originally Posted by RandallNeighbour

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.

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!

Originally Posted by bc993

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!

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

[BoxsterLS376]

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

[BoxsterLS376]

Been thinking of doing it with some electric turndowns so I can have a Jekyll/Hyde option 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 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

[Boxster 50]

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. Thanks again for the updates and the pics !!! Good luck on the test fit.

[BoxsterLS376]

Originally Posted by Boxster 50

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. 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]

Great project! Subscribed.

[RandallNeighbour]

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.

[JRL]

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.

[BoxsterLS376]

Originally Posted by JRL

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~

[BoxsterLS376]

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

[Qmulus]

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?