Intake almost done
 

Greetings everyone,

Got a bit more done and will hopefully get back over to the shop today~ Intake is almost fabricated, I think I am going to forget about the factory box due to potential restrictions and just go with a cone filter and create a cold air box.

One thing which I didn't really think about was the fact that the GM MAF sensor bung is aluminum, not steel so you will need to have some aluminum tiggin' skillz and straight aluminum pipe plumb it into. Unfortunately I already got the 4" steel pipe so I decided to make it work, plus my aluminum tigging skills are shall we say not that great :p so... JB WELD TO THE RESCUE!!!!

I sometimes forget how awesome JB Weld is - scuff it up a bit, lay it on, then a nice final finishing finger weld and BAM!! Like it cam out of the factory that way!


So otherwise I also got started on the cooling system a bit... In case you don't remember the original motor cracked a cylinder head or something and the oil/coolant started to mix badly in the end. At minimum the entire cooling system needs to come apart for cleaning which is what I am starting on.

I decided in stead of spending money to have the 3 radiators, coolant reservoir and the heater core properly cleaned I would rather put it towards new parts as the stuff on the car is already 15 years old so I think it is the right way to go.

I have talked to quite a few people who have had trouble cooling these motors in other applications and really don't want to run into that issue so I am upgrading the radiators to CSF full aluminum, and getting a new heater core and coolant reservoir.

After pulling out the heater core yesterday I think I made the right call - the stuff coming out of it is nasty sticky goo, I'm sure the radiators are about the same.

Here are a few pics of the intake setup thus far~
Thanks for following~
J
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JJ, Your build reminds me of a day when I had much more ambition and energy, except you've MUCH MORE TALENT lol............Great thread..................:cheers:

The intake is looking really good. I wish I had some welding skills.

Hey,
Do you think it's ok to use an LS1 oil pan? Those low profile LS2 pans are impossible to find used, and they cost a fortune brand new. This is the one I'm talking about: F-Body Camaro/Firebird LS1 Oil Pan Dimensions

Thank you sir :)

Thanks a bunch! I am using a 30 year old welder so the welds are not as nice as I would like but I'm going to use a different one for the exhaust~ You just need to get a welder and practice a bit, that is really all it takes. I learned on my 1988 944 Turbo S which had a slight bend in one of the front supports due to the previous owners son having a slight offroad excursion over a curb. Bent it back pretty straight and went to town :p Definitely not pretty but it worked and I've been hooked ever since!

hrm... I would have to check out an LS1 pan to see. I'll try to run down the street to my friends shop, they use the LS1 pans to install the motors into RX-7's and actually take off the low profile LS2 pans (that is where I scored mine from! :p ). I'll check and see if he has any more although you may want to check Ebay, there was a whole oil pan kit on there for like $197 if I recall correctly, just took it off my watch list last week or else I'd provide a link~

I'll let you know what I dig up~
J

I think I just found an LS2/LS3 low profile pan for $200. Been looking for one for almost a month now, and the day I complain about it it shows up... It would still be nice if you are able to confirm for those planning to do it in the future. I tried to find out from Renegade and they told me any oil pan is fine as long as its not from a truck. I'm glad I stubled across your post about ground clearance issues before I made a dumb purchase.

This is such a bad A** thread!!!! I love my Boxster, but when I bought it and found out it had a spun rod bearing I was so tempted to go down the path of an LSx swap (I had a lot of previous experience with my 98 WS6 that I built). The potential is now almost limitless! In a year or two when you get used to the power and it no longer feels "fast" a cam swap and FAST intake manifold can net you another 100hp! Fuel system and cylinder heads can net you an additional 150! Why can the 3.2 be so easily modified :-(!!

Good luck, and again amazing job!!!

Cooling and exhaust~ Suggestions??
 

Good morning everyone,

Just figured I would chime in with a quick update. Nothing really exciting as I'm waiting on a few parts to show up and need to get some more stuff ordered but exciting things are in the works :p

I really dug into the cooling system this week and I did want to mention that I have decided that the entire cooling system needed a refresh. After cracking it open that was a great decision as this motor had cracked a cylinder head and mixed oil into the cooling system pretty badly.

The heater core, and all 3 radiators were filled with goo of the nastiest kind so ALL rubber hoses are being replaced with fresh ones, heater core has been replaced and for the radiators I am going with the CSF all aluminum units. They aren't cheap but it is definitely the way to go if you have had oil in your cooling system. You could waste money trying to clean them, but in the end you still have a 15 year old radiator and after looking at them, they were just about done anyway so it is the right call.

Once I get all the stock stuff replaced i'll dive into fabricating the rest of the system. Since it looks like I may be in this V8 swap thing for the long haul I am getting a pipe bender so that I can make as much out of aluminum pipe as possible. It the end it is much cheaper then ordering a bunch of bent pieces, plus I can hopefully make them exactly how I want. Ordering some 1.25" and 1.5" aluminum straight pipe to make it with.

***EXHAUST***

*EDITED* Measure twice, buy once. Don't trust everything you read on the internets~

My plan at this point is to work from the headers back - 2.5" stainless steel flanges with a 2.5" to 3"expansion pipe, a few bends, then a set of magnaflow catalytic converters, magnaflow mufflers then making a custom tip from with the 3" stainless.

I'm going to try and have everything ordered by this evening so I can have it by next weekend so chime on in!

Thanks!
J

So it looks like my plans for a 3" exhaust may be foiled by the muffler... looks like the biggest size I can get is 2.5" in/out on the same side. Anyone know of a muffler out there which has 3" in/out on the same side? Otherwise it may be a 2.5" system using this muffler - http://www.summitracing.com/parts/mpe-14210

http://www.spintechmufflers.com/mufflers/race-mufflers/400-psc-180-series/cat_18.html

344SCT Sportsman Splitcase 3 - Sportsman SplitCase 300SC Series - SPLIT CASE 300SCS & 300SCT - 344SCT Sportsman Splitcase 3" inlet 3" Outlet @90 Degrees - SpinTech Performance Mufflers

Might use this on my setup...

maybe this might help.

Thanks for finding these! May be good for a future project :) I've been researching and gotten a PM or two (Thanks Bill!) regarding the exhaust and some other bits. It looks like 2.5" should be fine and is what Renegade is using on many of their cars. I went ahead and ordered most everything and it is trickling in this week.

Got a few of my new radiators/hoses yesterday and the mufflers showed up as well. Don't know if the rest of the fabrication stuff will be here before the weekend or not but putting the cooling system back together should keep me busy enough, then next week can start making the exhaust and the rest of the cooling system.

Also sounds like the cooling system could be lacking due to the water pump inefficiency so that needs some more research~

I'll get some pictures posted of the radiators and stuff soon, probably another video too because it is easier :)

Thanks!
J

Cooling system update~
 

Greetings all~

Dug into the cooling system last week and wanted to share what I've found... So far it's pretty ugly :)

I did make the decision to go ahead and order the CSF aluminum radiators and am glad I did. As soon as I pulled off the bumper and started to loosen the radiators I knew it was the right move. Radiators were fairly clogged up with road debris in between the radiator and A/C. When I started to take off the hoses they were pretty shot too so they are getting replaced as well.
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Since this car's motor failed with oil getting into the cooling system is gucked it up something baaaaad. Already got the car on a lift at the shop so I should be able to pull the rest of the coolant pipes to clean them so I can have it wrapped up this weekend. You can see the poo in the video.

http://youtu.be/q5fBq6p1Mkk

So this week more stuffs continued to trickle in and got my radiator and many hoses, although I think I need more. Amazing how many hoses are on these damn cars!! Also got my air filter so I can finish up the intake as well. Also got the mufflers and my pipe bender so once my next order from Verocious arrives we can start fabricating the rest of the cooling system and make the exhaust!
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Thanks for following~
J

Thanks for the video update, looking great:cheers:

Thanks Bruce, I appreciate it! :)


Well no video from this weekend as I was to tired and not that much to report to make it an exciting enough video! I was able to get all of the coolant pipes and hoses pulled out and cleaned this weekend, got all the new aluminum radiators installed so that part of the project is about 95% wrapped up, just waiting on a few more coolant hoses then I can strap the bumper and fender liners back on and that will be that~

It looks like the rest of my exhaust and cooling system bits will be here tomorrow so as long as I can motivate myself to spend another weekend in the shop then this bad boy is going to be pretty darn close!! I also ordered an IMI starter from Kennedy Engineering - I think it was like $239+ shipping... hopefully that shows up soon too.

Still a few weeks out I'm sure as I do need to make the whole exhaust system and fabricate the cooling system but hopefully that won't be too bad.

Stay tuned!
Thanks :)
J

Renegade should be paying you

I love that the Boxster has two trunks. Lots of space to store all the parts :)

How long do you think until you have it running?

Well they have my address but haven't seen a check yet :p Thanks!

Haha yeah lord knows I have used up every bit of that, plus everywhere else to throw stuff although this weekend I thinned out the pile quite a bit getting those radiators in...

There are still a few major hurdles which need to be tended to and I want to take my time to make sure it is pretty much tip-top before I try to run it. That being said I really need to sit down and make a list of things to do, guess I can start here...

1. Wiring - There are not that many wires required to get the GM motor running... only about 4 I believe, but to make it talk and jive with the car will require a bit more. Also need to tap and re-thread the cylinder head to accept the Porsche coolant sensor, then figure out where to wire that into the system. May need to pull the motor back out to tap it properly :/

2. Cooling system - I should have about 85% of what I need today but still need to order an inline thermostat and some T's for the cooling system. Need to fabricate all of the piping to connect the new motor into the existing cooling system. Also a bit more research on the coolant reservoir itself... pretty sure i'll use a factory reservoir, just need to figure out how to plumb it correctly.

3. Fuel System - I have used the factory fuel line which runs for the filter to the back of the engine compartment and need to adapt it to the GM fuel feed which may be as simple as a rubber hose and some clamps, but I really doubt that :) I have some questions which some of you may have answers for... My biggest concerns right now are I believe the GM motor does not appear to have a return fuel line back to the tank so I don't yet know how that will affect the Porsche system. Plus all the fuel vapor lines and stuff, maybe you just plug them up? We will need to do more research on this...

4. Exhaust System - I should have everything I need to do this today and I am pretty confident on this one. Good plan in place and will just take a bit of time to fit everything in correctly as I need to go ahead and get the axles, lower bracing and underbody tray stuff in place to make sure it all fits...

5. Intake system - Almost wrapped up, just need to properly mount the new air filter and fabricate a cold air box or at the very least a good way to shield the filter from the exhaust system.

6. Hand controls/Interior - This is something I was thinking about this weekend as the emergency brake holder had to be relocated lower into the tranny/coolant tunnel so i'll have to figure out how to mount that back in properly. Also the shifter and cables should not be a big deal but may need to get some flame proof shielding as they will need to run down by the exhaust on the passenger side...

7. Reassemble the car!!! I'm sure there are things I'm missing but once all is said and done and running with the V8, the car is still in about 1000 pieces!! It just all takes time :)

So in looking over my newly made list I'm sure I'm still a month off or so... unless I take a week off work, to come into work, to try and finish it... :D

Damn I need a vacation!!
Thanks everyone :cool:
J

Wow, can't wait to see this thing run! Great job. Thanks for sharing÷

You and me both!! Thanks :D

Well got my shipment of bits from Verocious today and looks like one of the mandrel J-bend pipes wasn't shipped, but hopefully they'll be able to get that here before the weekend.

I did a quick test run bending the aluminum pipe with my el-cheapo pipe bender and clearly more strategy will need to be used as the pipe is not bending as cleanly as I hoped. Need to try filling it with sand and see if that helps... hopefully things work better with the 2.5" stainless or I may have wasted money on this pipe bender!

Got everything else for the exhaust, flanges, catalytic converters etc so hopefully we will make some more progress this weekend!

Thanks!
J

Got my IMI Starter~
 

Hey guys,

Got home last night with another package waiting on my porch, turned out to be the starter I ordered! YAY! I did try to buy it directly from IMI but you have to sign up on the website just to see pricing, so I just called up Kennedy who makes the adapter plate kit and they sell the starters - easy peasy. You may be able to find them cheaper elsewhere but for this one I figured I'd go right to the people who made the adapter plate to make sure I got the correct one.
The adapter plate kit can use a factory GM starter or an IMI high torque starter - I opted to go with the IMI as factory starters are pretty pricy at around $300~ This one set me back $235 plus shipping & handling which came in at a somewhat ridiculous $25~ for UPS ground but whatever, it is what it is. The price seems to be better then anywhere else based on a quick google search so I'm fine with it.

The other advantage to the IMI starter over stock other then being a "hi-torque starter", is that the starter can be clocked to 4 different positions to accommodate more clearance from engine/exhaust. I'll show it in the pics/vids this weekend~

Part number for the starter is IMI-140 for those who are interested~ But if your configuration is different then mine you may want to call and double check with the folks at Kennedy - they are great and will make sure you get the right stuffs~

Thanks
J

Are you saying I have to get a GM starter too? :barf: lol dammit. :ah:

Well if your plan was to use the Porsche starter then yep, sorry. You can find good used or rebuild units out there which will cost less then going straight to GM but I think they will still run you around $180-$200 so for a bit more I just got the IMI.

Good evening everyone,

Been a bit under the weather the last few days so haven't got as much done as I wanted but tomorrow is a new day so we will see :)

Decent video update today and answered some of the questions I've been getting. If you have any others just let me know and i'll do my best to answer them.
Thanks!
J
Video update 3.28.2015 - https://youtu.be/zYu6f_g-rSE

Greetings all,

Dragged myself back to the shop today and worked for a few more hours. Trying to get all the little thing in place to make sure my exhaust clears everything... A few things to note~

Well the starter is really being a pain in the "enter edited expletive here". :mad: The oil sender just simply unscrews from the oil pan as suspected, but even with that out of the way there does not seem to be enough clearance for the starter. I've loosened up every cradle bolt and tried to move the bars around to clear it but so far, this ain't gonna work. I didn't want to frustrate myself to badly on a Sunday so I just walked away.

Also tried to bolt up the A/C bracket and so far it looks like the damn holes don't quite line up... :mad: The top two line up but the bottom is no-go, not off by much but enough to not fit. I'll triple verify it before re-drilling the mount when I have the motor out again but this is starting to get ridiculous...

So I decided to go ahead and start playing with the exhaust and hope that everything turns out OK in the end! I got the down pipes and fitment through the axle area taken care of today. The exhaust is pretty close to the axles but that is as close as it is gonna get, I don't plan any Dukes of Hazzard style jumps but if I do it should still clear :) I may make a small heat shield for the exhaust there or possibly some header wrap to keep the CV boot from cooking, well see how it looks once it's on the ground.

Thanks~
J

Video Update 3.29.2015 - Exhaust - http://youtu.be/7Bh4i0-o6Ws


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One more exhaust pic to show why I think an x-pipe may be the best solution. This is all just mock-up resting in place and will not look this way in the end... just brain-storming really.


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It's gonna be tight but hey what's new!!

Oh and don't be afraid to chime in and join the conversation... it's starting to feel like I'm talking to myself in here :rolleyes:

Here is a picture of one of my awesome cats - she loves America too :cool:

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Hard for me to comment - I'm just blown away by your craftsmanship - tenacity - and great attitude. I may have set the beast on fire by now.

One thing I've been thinking about is using the crate motor set up for a carburetor but use a 4 bore EFI unit. But until I see how the intake would work as a down draft and if it would interfere with the top when it's down I'll just keep thinking.

Seems like that would get the intake out of the heat - simplify installation - eliminate a lot of pipe fabrication - eliminate the oil pressure relocation - eliminate the cutting of the trunk floor - and the cost are not over the top. The system should also be smog compliant and pretty much self tuning. Just a thought.

I had intended to drop by but picked up the worst case of flu on earth when I went down to Amelia for the Concourse - figured you wouldn't want me within 1,000 yards of the shop. Maybe next week.

Randy

Just sitting here enjoying the show. Keep up the good work! I have a 97 that you're almost inspiring me to go with a V8.

We are here;) Take a look at the views on your thread, over 17,000! I don't have anything to contribute and why clutter up the thread? Great information, and I love the pictures and videos. Keep up the great work:cheers:

Hey Randy,
Sorry to hear you're not feeling well, hope you get better soon. I definitely appreciate the compliments! Yeah I think the biggest problem with a carb/EFI unit would be the intake, top up or down because you would essentially have to expose the air clearer outside of the engine compartment. It is possible to set up a cold air type system using the intake on the side of the car but would take some kind of custom intake to route the air up there.

Feel free to drop by when you are feeling better and i'll show you what I've gotten done~
Thanks!
J

Excellent! Glad it is still keeping everyone's attention :) Some of these little things are tedious and not very exciting so just making sure no one is asleep! :D

I hope this does inspire you! Just keep in mind though if you start with a 97 it is going to take even more work then this project I've got going... it is much better to start off with an "S" model if you can. Better transmission, brakes, cooling, suspension etc. so many things you will want to change after a V8 is in there so keep it in mind!

Haha thanks Bruce, I appreciate it!! Hopefully soon enough we will get to fire this bad boy up and make things more exciting :cheers:

:D

Hey,
Have you drilled new holes for the hand brake cables yet? I'm just wondering how renegade runs it to the handle.

Vlad

Hey Vlad,

I have not and actually haven't bothered to ask Renegade how they did it~ Doesn't seem to complicated but just more stuff that needs to be done. I am actually getting pretty close to that now so hopefully I'll give you an update on that soon.


Greetings everyone else,

Sorry for the lack of updates - I've been a bit under the weather the past few weeks and progress pretty much came to a halt, but we are back to rocking and rolling again so I wanted to pick up where I left off with a quick video.

I was just about wrapped up with the cooling system last update so I wanted to point out a few things to be aware of regarding the new radiators and some rub points.
All the front end cooling system is back together now, 3 new CSF all aluminum radiators, new Heater core and all new cooling hoses front to back! Got the bumper and headlights back on yesterday and it is starting to look like a car again.

Posted a few pics below of the problem areas you need to look out for on the upgraded radiators~

I'm also about to start working on this project a bit more during the week so I truly hope to have this bad boy running within a month now!

On a side note it looks like I may have a customer interested in converting his 2000 911 C4 which sadly just appears to have popped a cylinder head, or it may be available to purchase for a conversion but either way I've talked to a few of you guys and will keep you posted if it becomes available!~

Short and sweet video update finished up the cooling system will be available shortly~

http://youtu.be/4H0r_KcBG1Y

Thank you all for your support!
J

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About those transmission spacers~ I was wrong.
 

Oh yeah...:o

Sooo before I forget I have been trying to get some other things done including getting the accessories on like the alternator, starter etc...

Looks like I was wrong about the spacers for the transmission - not a big deal but so far I have found 2 definite problems with it. Just wish I hadn't wasted so much time with it now, but now I am back to clearance issues again as well so is a bigger pain in the rear for that reason.

So while the motor sits nice and level with the spacers so far I have found that the shifter counterbalance thingy hits the Renegade transmission cross mount if the rear of the tranny is sitting to low. I took about 1/4" of my spacing out and it now clears, but now the front crank bolt is hitting the damn e-brake mount again :mad:

The spacers are very likely the problem for why I was having problems getting the starter bolted up too although I haven't messed with it much I think that may sort itself out.

Sorry if I screwed any of you guys up :o
J

JJ the video link doesn't work - at least for me.

Hey Randy,

Give it just a few more minutes less then 5 I think - YouTube is still processing it.

OK working now~

Thanks!
J

It's working now - thanks - more good stuff.

Thanks Randy,

Not a whole lot of excitement in this video but the next few should really see things rolling again!

:)
J

Very cool
 

This is a great project. Enough in fact to get me to register just so I can subscribe!

-QB

The more posts I read the more I think this would not be the direction I would go. Sounds like it would be an awesome car when done but as a Kit, I'm trying to figure out where the Kit part is.

You are a glutted for punishment but no question have to be admired for you persistence and passion.

When that thing is done, I hope it is the beast it seems it could be

I will keep following. Keep posting your progress as this is akin to watching a climb of Mt Everest

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Yes, aint that the truth! I admire the gumption it takes to do this project. Talking to Renegade, it's virtually "plug and play". not so...

Having ridden in a V8 powered Boxster, however, i can attest that when it is done, it will have been worth it :-)

Thanks everyone for the kind words!

Yeah this has been challenge for sure but I know it will all be worth it in the end!!