BoxsterLS376 introduction - LS3 conversion :)

[Topless]

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.

[DNR]

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.



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

[BoxsterLS376]

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!
J

[Lcrivers816]

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.

[BoxsterLS376]

Originally Posted by Lcrivers816

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

[Lcrivers816]

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!!

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!

[shockandawe]

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.

[BoxsterLS376]

Originally Posted by Lcrivers816

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!!

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!

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

Originally Posted by shockandawe

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 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!!!

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

[martsink]

I'm so glad I found this thread. I'm about to begin a project of my own but with a lesser budget. Got an aluminum LSX block that I want to put in a Boxster S. The only minor problem is that I'm still looking for a roller

[JRL]

Hey John,

It's been a few weeks since we last communicated so it's about time for another visit. What is a good day and time. Don't want to crowd your space or irritate your boss

Randy

[BOOTLEG]

I have my 01 S Roller. Looking for the right LS. I agree with 376's logic on the crate LS but would prefer a more economical option. Commentary on other LS options? Seeing L33 pullouts on EBAY ~$1-2K. Anybody thought about LFX?

[martsink]

Originally Posted by BOOTLEG

I have my 01 S Roller. Looking for the right LS. I agree with 376's logic on the crate LS but would prefer a more economical option. Commentary on other LS options? Seeing L33 pullouts on EBAY ~$1-2K. Anybody thought about LFX?

I got a 5.3L LM4 Aluminum truck engine for $500. It came on 03-04 trucks. Gonna need to swap out some parts to Camaro/Corvette, but it seems like a great start for a budget build. I might get 799 heads and an lS6 cam if I have some extra $.

[BoxsterLS376]

Greetings all,

Cheaper motors can definitely be found out there, but don't forget that generally you get what you pay for!

This is one you may want to keep an eye on, 50K miles motor and trans no reserve... only @ $400 with 2 days left~
1998 Camaro Engine LS1 and 4L60E Tranmission LS2 LS3 LS7 LS9 LSX 69 Camaro | eBay

One suggestion is trying to find a C5 Corvette motor as it may save you a bit. It is a bit more money, but it is a bit more motor too~ You will need to swap out the oil pan to a C5 pan, plus if you can get the aluminum motor mounts with it that will save you about $300-$400 all together. Here is one on Ebay for $3400 with ECU & wiring~ 2000 Chevrolet Corvette C5 LS1 5 7 Liter Engine with ECM 87K | eBay

Hopefully i'll get the motor back in the car tomorrow and try to start figuring out the wiring~
More to come~
Thanks!
J

[martsink]

Is the clutch that comes with the kit proprietary to the kit, or can I get away with the stock Boxster clutch? I'm about to place an order with Renegade and I'm trying to figure out what I need and don't need. My engine is a pretty stock 5.3, so I don't think I need a performance clutch just yet. Thanks!

[BoxsterLS376]

Originally Posted by martsink

Is the clutch that comes with the kit proprietary to the kit, or can I get away with the stock Boxster clutch? I'm about to place an order with Renegade and I'm trying to figure out what I need and don't need. My engine is a pretty stock 5.3, so I don't think I need a performance clutch just yet. Thanks!

Quoting Renegade the stock clutch "will work" but really not going to take much abuse so unless you want to do a clutch job soon after your new install I'd go ahead and get the upgraded clutch... it is simply a Kennedy Engineered product...


Made some more progress as things are really starting to come together, although there is quite a bit left to do to get it running, feels like we are getting somewhere. Motor is pretty much in its final resting place as all I need to do is make a few more spacers for the transmission mount to lower it a bit, but everything now has clearance clarance!

Bought time to shell out some more dough to get this bad boy running! I've got some adapter plates being made for the throttle body, pretty sure I'm just going to use some piping with a 120* bend for the throttle body adaptation, didn't really get into any of that in the new video but check it out and let me know if you have any questions.
Thanks!
J

http://youtu.be/qC2iBviLzrg

[shockandawe]

Does Renegade cut the same amount of sheet metal when they do the conversion? Is it necessary to cut so much? The spacers you made for the trans mount ,did they tell you that it was needed? If so shound'nt they have been included???

[Pdwight]

I dont have a "Dog in the race" but the more I read and follow this thread the less impressed I am with Renegade and the more impressed I am with you BoxsterLS

If they are going to sell a turnkey kit it should be just that with complete detailed instructions on how and what is needed for this undertaking.

[BoxsterLS376]

Originally Posted by shockandawe

Does Renegade cut the same amount of sheet metal when they do the conversion? Is it necessary to cut so much? The spacers you made for the trans mount ,did they tell you that it was needed? If so shound'nt they have been included???

Hello,

Guess that depends on which sheet metal you are referring to and what kind of accessory setup you are running, water pump, alternator etc... With regards to the front of the engine compartment where the emergency brake is relocated then definitely some needs to be cut if you are running the Renegade water manifold as the motor tucks in far enough that you have to cut the area where the shifter cables go through to make clearance for the manifold. Metal is also cut away where the ebrake holder is so that need to be relocated unless you don't want an e-brake which is possible if it is a race car I guess~

Also the sheet metal where the front motor mounts hang, you could probably trim less depending on the accessory setup, but with the Renegade A/C and alternator mounts that area needs to go~

On the back on the engine compartment I probably cut more off then they did but I looked at the area and it basically only serves as a drip tray so I cut away whatI thought was unnecessary and can weld back something if needed.

Regarding the spacers etc.... this is a custom installation and in no way did I jump into it thinking it would bolt right up. There are several things along the way which I feel should have been disclosed from the onset when I was asking very specific questions. Small things like spacers and bolts were expected, I think the biggest thing which pissed me off was the motor mount situation as I asked very specifically about anything else I would have to buy, and no mention was made by them until I has a long weekend to get the motor sorted out and found out I didn't have everything I needed Come to find out that the WEVO transmission mounts were even a custom application for this exact install - V8 to Boxster conversion, but yet I didn't find that out until I called and asked about them specifically after seeing them in their pictures on an installed car

All that aside they have still been helpful and responsive, but I would really think for $7K it wouldn't be that hard to make this kit/install a LOT more user friendly...
:dance:

Originally Posted by Pdwight

I dont have a "Dog in the race" but the more I read and follow this thread the less impressed I am with Renegade and the more impressed I am with you BoxsterLS

If they are going to sell a turnkey kit it should be just that with complete detailed instructions on how and what is needed for this undertaking.

Thanks much for the compliment! I'm hardly reinventing the wheel here but definitely pointing out some shortcomings of the kit and hopefully helping folks to understand what they are getting into before getting $20K in the hole on a project~ Like I mentioned they don't really advertise it as a "turnkey" kit, but they do offer a turnkey package which will cost you $30K and now after going through the process, I can definitely see why. It is a lot of work. But if I do this again it will go much much smoother, plus this is a side project and not something I can just sit down with for a few weeks and bang it out, although I'm sure it could be done.


Quick update too, I had some time to test fit one of the axles and it really appears to fit quite well, geometry dosn't look too bad either so hopefully nothing to worry about there, just have to see if they can harness the ponies Also found a place that specializes in LS wiring harnesses so i'm gonna call them and see what they can offer to make this a smoother install~

Thanks!
J

[BoxsterLS376]

According to my invoices the Hinson Supercars part number is #4050 and the WEVO transmission mounts were listed as WEVO Boxster BLUE

[Lcrivers816]

Thanks brother! You're the best. I'll keep you posted on my build!