Project update

[redpepperracing]

I didn't think this was appropriate for the DIY project forum, since I'm not really going to explain how I did anything, just what I did. It's been a 2 1/2 year process from when I got the check engine light and determined my variocam pads were worn out to now, and almost being ready to put it back on the road. There was a lot of down time since I got frustrated with the process, and the seemingly daunting amount of work, but thanks to some prodding and lots assistance from my buddy, we got it done, and now it's down to the minor details. It's a 2000 base Boxster 2.7, now with the following mods/upgrades, from front to rear;
- 3rd rad (kit from ECS)
- front and rear sway bars (Eibach)
- front and rear shocks (Koni)
- front adjustable sway bar end links (homemade)
- electric power steering conversion
- AC delete
- 987 150A alternator
- 996 intake manifold and runners
- 987 throttle body
- 987 air intake and BMC filter
- 996 oil heat exchanger
- new coolant reservoir
- new coolant hoses (rear)
- SAI delete
- 160 degree thermostat
- hardened steel oil drive
- 996 oil pressure spring
- new variocam pads (duh)
- new timing chain tensioners and new chains
- new spark plugs
- adjustable trans mounts
- adjustable shift linkage (homemade)
- Numeric custom length shift cables
- BAD shifter

Items to complete: AEM wideband install, custom exhaust, braided steel brake lines, custom tune

And probably some more stuff I'm forgetting. Anyway, here are some pictures:

Front end with homemade grills:


Intake manifold:


Adjustable end link:


Electric powering steering


Short serpentine belt:


Throttle body:


Shifter and cables:

[redpepperracing]

I can't forget the custom coolant tubes my buddy made by welding the stock 986 and 996 tubes together for the 3rd rad conversion:


You can also sort of see the 3d printed hose clamps I made since all of them broke when I took them out originally. Also obviously the power steering lines, which I have not checked for tire clearance yet, fingers crossed...

[Qingdao]

Cool progress, tasteful upgrades.


Your shifter cables..... Did the company that made them give you and option of getting longer cables made?


My next 986 is gonna be a bit longer, and shifter cable length is bound to be one of my issues. I kinda thought about extending the rod section inside the cabin, but I don't think that is going to be long enough of an extension that I will require. I need like 3'.

[redpepperracing]

Yes, Numeric made them for me and I believe they were 2 inches longer than their stock 986 length. I needed the extra length because the 996 intake is taller, so I had to lower the engine and trans, and the stock cables were too tight for my liking. I didn't know Numeric actually made custom cables, I had just sent them an email asking about the cables, and they called me about 30 minutes after I left the message and he told me they can make them any length you need. I believe they charged me $75 for the customization, but he also discounted the cables by about half that so it was reasonable enough for what you get. The ones I got are a bit too long, but I was guessing on what I needed. It's better than them still being too short, so if you can get a good handle on the exact length you need, they can build them to suit your requirements.

[Marc_986]

Really nice to see this project!

And some questions straight away as you know I have some similar features in my car..

- Did you already get a chance to test with this belt routing? My engine will also be without AC and PowerSteering pump, so I guess that is the same as yours. I was considering to put the AC compressor back just to function as an idler. In your routing, you now have the tenstioner on the 'wrong' side of the belt if I see it correctly. Typically the tensioners are on the return side of the belt where there is no load on it, just the tensioner taking up any slack.

- You mention you have lowered the transmission and engine together. How did you do that and did you have to modify the chunky brace between both control arms? My upcoming V8 might also require me to lower, but there doesn't seem much space till I hit this brace.

- Just for my interest; why did you go for the third radiator? I sort of went the other way and focused on increased flow (less pressure drop) to the existing radiators by using the Boxster S pipes and hoses. I used two additional simple radiator hoses to avoind the T-piece going to the center radiator. I actually do have the third radiator around here with bracket, ducting and hoses...

Really interested to hear your experience with all the upgrades when you do have it back on the road. Close now!