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Posted by: precisionchassis Jul 26 2010, 05:08 PM

I know there may not be a lot of people on here who will be interested in this for their car, but it will be nice to have more options for people who want more power, and a modern shifting mid-engine transaxle. These pictures are of a 6 speed version, but the 5 speed will use the same adapter plate and flywheel.

Posted by: daveyboybadion Jul 26 2010, 05:21 PM

That's cool, are you selling the adapter?...daveyboy

Posted by: jimkelly Jul 26 2010, 05:25 PM

the shoe prints on the wall - big distraction : )

Posted by: andys Jul 26 2010, 05:36 PM

Did you have to notch the bellhousing to get the starter to fit?

Andys

Posted by: precisionchassis Jul 26 2010, 05:42 PM

Yes

Posted by: precisionchassis Jul 26 2010, 06:22 PM

Yes, the plan is to eventually sell an adapter kit.

Posted by: charliew Jul 26 2010, 08:07 PM

I wonder what is the torque specs for the boxter 6 speed and what is the first gear ratio? If the boxter 5spd is higher than 300 ft lbs torque rating it may be a worthwhile investment. It costs about 3500 to upgrade a suby 5spd I think to handle 450 ft lbs where the case becomes to weak part. At any rate it is nice to have a alternative as this should also fit the suby 6. What is the distance from the center of the axle to the motor bellhousing flange? The adapter also appears to move the motor further forward which is good I think. Also the tranny looks more robust in the case webbing than a suby tranny.

Posted by: BIGKAT_83 Jul 27 2010, 08:43 AM

Great work!!
I guess its time to start looking for a Boxster with a bad engine. How much lighter is the Subaru engine than the 2.7 water cooled boxster engine. I'm guessing that the subaru is at least 200lbs lighter if not more.


Bob

Posted by: tommy914 Jul 27 2010, 08:52 AM

will this use the cable shifter from the Boxster? or a custom setup?

Posted by: precisionchassis Jul 27 2010, 01:01 PM

I'm pretty confident I can make the stock Boxster cable shifter system work in a 914, but won't know until I try. Cable length will be the deciding factor. Regardless, there's no reason not to use the shifter itself. It would just be a matter of some custom cables. The first conversion will happen in a Boxster S that will be a track car. As long as all goes well in that car on the track, I will venture out to a 914 chassis.

Posted by: budman5201 Jul 27 2010, 04:19 PM

Hey are you making this adaptor? I am VERY interested. I just took a good look at the boxster cable shifter setup at 20th Street porsche junkyard here in Phoenix. It is a real nice light setup and cables are pretty long stock. I can get the whole setup shifter and all the cables, plus the rear brackets that bolt to the transmission for $150.

I bet this would be a perfect fit for my subie 6.

So i have a few questions.
1. clutch, how is this setup?
2. flywheel\pressure plate setup, are you making it?
3. how soon till you get this setup done?
4. Which transmission the 5 or the six speed is better, are they both computer controlled??

thanks man, very interested!!

Oh hey !! I just saw I live right next door to you in Chandler.....Would love to come and see your setup.

Posted by: precisionchassis Jul 27 2010, 04:28 PM

Clutch will be stock style Boxster pieces
Flywheel will be completely custom
Should hopefully have the test car running and testing by the end of the summer
6 speed is stronger than the 5 speed but slightly heavier and more expensive. Both use the same adapter plate, clutch and flywheel. Neither are computer controled.

I am making the complete adapter kit and conversion kit myself.

As you already know, the same adapter plate will work for the EJ, EG, and EZ Subaru motors.

Posted by: budman5201 Jul 27 2010, 04:52 PM

If the price is right, I'll be your first buyer for the Complete kit so i can just buy the transmission and bolt that baby in!!

If you need a test subject, my 914 subie 6 is up and screaming around already. I'd be glad to put that adaptor kit through its paces.

I am sure the gear ratios will bring my rpms down quite a but while cruising at 75mph.

Posted by: precisionchassis Jul 27 2010, 05:08 PM

Thanks, but I already have a 914 test vehicle that I will be putting the first 5 speed into...

http://www.precisionchassisworks.com/subaru-wrx-powered-porsche-914.html

Posted by: Zaney Jul 27 2010, 06:29 PM

Is this your http://www.youtube.com/watch?v=g4cVMmJKyLg swap?

If so, AWESOME craftsmanship!!!

Posted by: precisionchassis Jul 27 2010, 07:09 PM

Yes it is. That was a fun car.

Posted by: precisionchassis Jul 29 2010, 03:54 PM

New body work mocked-up on test car...

Posted by: rickthejetman Jul 29 2010, 04:12 PM

about how much does a boxter trans cost? 5spd or 6spd?

Posted by: precisionchassis Jul 29 2010, 05:07 PM

A good 5 speed is about $1500, and a 6 speed is about $2500. I've seen them for less on Ebay, but those are good "retail" prices from reputable salvage yards.

Posted by: andys Jul 29 2010, 05:20 PM

The Boxster 5 speed and the Audi 5 speed model 012 are the same transaxles (same output flanges?). There are some gear ratio variations, but most of the 1.8T Audi's have the same ratio as the Boxster. Only thing you don't get with the Audi transaxle is the cable shift bellcranks and linkage. The Audi stuff can be had for about half the cost of the Boxster.

Andys

Posted by: precisionchassis Aug 7 2010, 10:41 PM

I just pulled the stock M96 engine out of the donor Boxster and put it on the scales. The fully dressed engine without flywheel/clutch/pressure plate weighed in at just over 450lbs. STUPID PORSCHE!!!

From the research I've done, the twin cam, turbo 2.5 Subie motor should weight around 320lbs which includes the exhaust manifolds, turbo, intercooler core, PS pump, flywheel, pressure plate, and clutch disc. I haven't weighed the exact engine that will be going into the car because there are still a lot of pieces that need to be fabbed yet, but I predict a 100lb savings with the Subaru motor.

Posted by: charliew Aug 9 2010, 07:01 PM

I think because of the weight of the 914 the highest axle ratio offered will be the best for the 914 application. Also if the first gear in the six speed is as low as the sti 6 spd it will be pretty much usless except for towing in the 914.

Posted by: precisionchassis Aug 9 2010, 11:42 PM

The gear ratios between the STI and Boxster 6 speeds are very similar, but the Boxster final drive is 3.44:1 and the STi's is 3:90. I think it will be just fine

Posted by: charliew Aug 10 2010, 03:16 PM

I agree, it sounds like the boxter gearing is better for the 914 than the sti tranny for a 300hp or better motor, I'm not sure how heavy the boxter body you are using is though for the first application. Will the boxter clutch and ppl handle 350-400 ft lbs?

Posted by: atsealevel914 Aug 11 2010, 08:13 PM

Posted by: DBCooper Aug 11 2010, 08:53 PM

Is part of the plan to put Subaru engines in all those early Boxsters that had their motors go crispy? If so you got a PLAN dude! And I'm in line for one myself.

Posted by: Jake Raby Aug 12 2010, 12:07 AM

I have a 49K mile 6 Speed Boxster S tranny for sale.. 2250.00 takes it. Came from a car that was parted out due to IMS failure.

Posted by: precisionchassis Aug 12 2010, 03:55 PM

This is EXACTLY the plan! I think VERY soon there will be a TON of these early Boxsters in the $3000-$4000 range with bad engines. I want to be ready when it happens...

Test fit the engine today to see how it fits. It's almost like it was meant to be. It almost looks like the turbo might be able to fit in the stock location on the engine, although that's not what I will be doing on this car. There is almost 6 inches between the crank pulley and the engine bulkhead which is WAY more than the stock M96 engine.

Next is motor mount fabrication.








A stock Boxster S weighs in at about 2940lbs. The test car will weigh about 2300lbs with a full cage and track prepped. The classes I'm planning on running it in at first is NASA's TTS and ST1 so I will be limited to a power-to-weight ration of no less than 8.7:1.... so about 280ish to the wheels.

Posted by: DBCooper Aug 12 2010, 04:08 PM

Actually you can find them already, so I believe you've got this one by the tail.

There's irony here. Poor Jake. Lately I've noticed that in forums where he used to spend a lot of time talking up T4 conversions, Shoptalkforums, Spyderclub, etc. the Subaru conversions have taken over. Not so many T4's any more, they're just too expensive. So Jake shifted to Boxster motors, which are a problem. Now you come along developing a way to put Subaru motors in Boxsters, too, again because the Porsche motors are so much more expensive. Subaru's are going in to everything, and seem to be following Jake around. No wonder he's so annoyed.

Posted by: charliew Aug 12 2010, 04:24 PM

A stock 2.5 04 sti is about 240-260hp at the 4 wheels so a 2wd version probably is about 280. The boxter looks like a better fit for the suby waterpumper and all the suspension is much newer and later technology. I have a boxter cable shifter though and the mr2 shifter seems like a much cleaner mechanism to me. Course the stock shifter already works and plastic doesn't rust.

Actually Jake would probably make a great suby motor builder. Everyone knows it takes close attention to detail to build a good motor and the suby does have some challenges if it is entended to be a performance motor at 7k. The stock turbo motors pretty much run out of steam at 6500.

Posted by: precisionchassis Aug 12 2010, 04:34 PM

The donor car I'm using was bought for $3500 (for a 2000 "S")because it had a bad engine that was mixing coolant and oil. I've seen 2.5 cars go as cheap as $2500 with bad engines

Posted by: DBCooper Aug 12 2010, 05:20 PM

He's said he'd rather be shot in the head.

Posted by: Jake Raby Aug 12 2010, 09:04 PM

It doesn't bother me a bit. The Boxster is just another car and the Suby conversion just makes sense.. Our aircooled backlogs are just as strong as they were in 2000, I might lose two sales a year to the Suby conversion for a 914, and that's fine because those people aren't looking for what we create anyway.

In the M96 world our work is to support shops, sell information and create engine solutions. We are not building high numbers of the engines and don't want to.

The Suby might be growing but we have grown 400% here in 7 years and it shows zero signs of slowing down.. During this horrible economy I have added employees and added TWO more buildings, both of which are paid for. If even 1/2 of all Boxsters were converted to suby power there would be more M96 busines than we could ever want.

BTW- We haven't shifted any focus, we have just expanded. The same people are working in the airccoled division that have been there for years. I added space, added capability and much more defined spaces to carry out work with the Boxster and 996 engines.

FWIW I did a suby conversion into a sandrail in 1994, it took about 6 months to finish and I took it to Glamis in April of 1995 for the first time. Been there and dome that with a 2.5 even before ole DB Cooper.

Posted by: DBCooper Aug 13 2010, 04:34 PM

Don't know about that, Jake, I started with a VW Manx at Pismo in 1968. And if I'm not mistaken that was before you were born.

So you're all annoyed for some other reason?

Posted by: RJMII Aug 13 2010, 06:59 PM

about jake already. You're reading annoyance where others might not. To me it looks like he is happy with where his busoness is going; and wishes the original poster similar success. If anything I would guess he is annoyed that you are hijacking a thread to try and provoke him.


Let's have some more pics on topic; this is one bad ass project and I want to see more!

Posted by: Jake Raby Aug 14 2010, 03:06 AM

Nothing is currently annoying me, not even DB.. That's because I expect this behavior from him and was absolutely awaiting the post he made since I saw the first posting of this thread. It's just what he does and that's fine by me.

I am perfectly happy! I can work on the property where I grew up, shoot my rifle or shotgun out my office window or go fishing at my pond that's 200 yards from my shop. I can work on whatever I want to whenever I want to do it all while working with a great group of employees.

BTW My reference to doing it before DB wasn't talking about playing on the sand, but rather utilizing the Subaru engine to take the place of the VW engine. Nothing wrong with the Suby at all, some people might be surprised with what I have been working with as an addition over the past few years too:-)

Those who come our way even for an enquiry are looking to us for a reason and that's not primarily the cost of admission.

I do wish this project luck and might even do a few of the swaps myself, Blake and I had this idea two years ago but my goal was to support the M96 engine because I like Porsches and I like working with engines that were originally plagued with issues.

There will always be a big enough following to purchase what we create at the low volumes that we want to service.

Now, Lets stay on topic and don't hijack this thread.
To the original poster: email me, I'd like to help you:-)

Posted by: DBCooper Aug 14 2010, 04:43 AM

Wow, could I be mistaken? Jake, I'm used to hearing you call my car a piece of junkyard shit and worse (in your forums for example, a pretty vigorous condemnation of Subaru conversions: http://forums.aircooledtechnology.com/showthread.php?t=2139). You seemed pretty annoyed then, but if that's all past and my car is acceptable now then apologies are in order. But I admit it's gone on for so long already that I'm skeptical.

This isn't a hijack, not at all. Jake's acknowledgment that this could be another reasonable solution for the poor Boxster owners left stranded by Porsche is a major endorsement. Write that down and quote it. I know this is one of the smartest and most creative solutions I've seen, and I'm rooting for it to turn out well because I want one for myself. Oh, I said that already.


Edit: Good idea Jim! There's now a Sandbox thread for Raby Related comments. Please don't pollute this thread, precisionchassis has too cool a thing going on. I keep going through those photos, which are incredible, and can't wait for more. Tempted to get a Boxster and just follow along.

.

Posted by: jimkelly Aug 14 2010, 06:16 AM

the sandbox exists for a reason.

that said - i am digging the idea of a boxster with a suby engine : ))



more pics and details pls.

jim

Posted by: 76-914 Aug 14 2010, 11:16 AM

sans the bickering. this is good stuff; let's keep moving forward!

Posted by: JRust Aug 14 2010, 11:43 AM

Love to see the work you are doing with the adapter plate. I am sure it will be getting plenty of use once finished. Both for the Boxter & our 914's. Do you have any interest in doing a plate for the 1.9 TDI motor?

Posted by: precisionchassis Aug 14 2010, 11:50 AM

I was under the impression that the VW TDI motors were a direct bolt-on for the 5 speed Boxster tranny... No?

Posted by: Mueller Aug 14 2010, 12:16 PM

no idea if it is a direct fit, but a question that is almost more important is will the gearing work for you? remember a TDI is going to have a completely different powerband, would suck to go thru all that trouble and expense and have something you don't want to drive due to poor gear ratios

Posted by: RJMII Aug 14 2010, 12:43 PM

If I were to send you a solidworks drawing of an engine, could you see how well it would match up to the Boxster S six speed?

Posted by: precisionchassis Aug 14 2010, 02:04 PM

Sure, the e-mail address is precisionchassis@gmail.com

Posted by: RJMII Aug 14 2010, 03:03 PM

Thank you! e-mail sent.

Posted by: precisionchassis Aug 14 2010, 05:37 PM

Prototype motor mount/cradle is finished. It mounts using factory hardware locations, and requires no chassis modification or welding. The bottom of the cradle also acts as a skid plate of sorts since the oil pan sits about a half inch lower than the stock oil pan.

Posted by: RJMII Aug 14 2010, 06:49 PM

That really does look like it belongs there.

Posted by: qa1142 Aug 14 2010, 06:59 PM

Now, can you make one for 914's

Posted by: precisionchassis Aug 14 2010, 07:02 PM

Yeah, the 914 will be next.

Posted by: JRust Aug 14 2010, 07:34 PM

Thats right! I'm getting so used to these dang adapter plates with my v8. I seem to think any conversion needs them . The VW motors are very torquey (is that how you spell that ) . So the power band doesn't concern me that much. I think stock HP is like 135-145 I think. Once they are chipped & a few mods I think you can push close to 200hp. But the HP isn't where it is at. The torque is sweet not to mention the gas mileage .

Okay back to the suby motor & your adapter plate. Sorry for the slight hijack. Love what you are doing with the Boxter. I've been keeping my eyes open for an older boxter with a bad motor. Mainly to scavenge the tranny & cable shift setup for a 914. Would love to have that mated to my current buick 215 v8 conversion. Be more tempting to just pull the motor & do your Suby conversion. Keep up the good work

Posted by: okieflyr Aug 14 2010, 08:20 PM

That is a cool conversion. But now I'm going to have too listen to their exhaust beat before I taunt them too much with the teener. I have a water cooled conversion that I've been running a 5spd 012 and Boxster shifter for a few years now, and LOVE the shifting! Rock On!

Posted by: jimkelly Aug 15 2010, 07:53 AM

sweet cradle : )

love all the photos of the boxster : )

has anyone determined the robustness of the boxster transaxle, realted to a stock 914 transaxle, a 915 and a 930?

does the boxster have power assist steering??

i assume this conversion will have catalytic converters and pass 50 state emissions? or will this be strictly a track car?

no shortening of the oil pan - that will save some time and money : )

jim

Posted by: GS Guy Aug 15 2010, 08:38 AM

Nice work - but make sure it all fits the EZ30R too! Some Boxter owners might not want to step "down" from a 6 cylinder to a 4. The 30R should slot in there just as easily!

Now if someone would just offer a good looking flare package for the Boxter and help it "man-up" a little bit!
Jeff

Posted by: RJMII Aug 15 2010, 09:56 AM

The boxster S six speed is STOUT. It's the same one as in the Cayman, and an inverted version of the one in the new 911 turbo cars. (whatever number they are doing)

It will very easily handle the HP and Torque of a well built Subie Turbo engine.

Posted by: budman5201 Aug 15 2010, 12:43 PM

ez30R and ej20turbo both fit in renegades cradle with no mods. So i bet they will both fit in your cradle too! I love my ez30R.

Posted by: Dr Evil Aug 15 2010, 04:40 PM

Wow am I thankful. I was wondering what I was going to blow my money on when I start making some in 3 years An EZ30R and an old boxter is a no brainer

Posted by: charliew Aug 16 2010, 04:16 PM

When you pull the pan on the suby motor check the pickup real close as they are known to be brittle from the brazing process at the block flange and the pan definately looks like it's against the pickup. a lot of suby pickups are too close to the pan and when guys jack the motors up against the pan bottom the pickup gap gets real tight and some pickups have broken either from vibration or getting fractured from hitting the pan.

Posted by: wittmer25 Aug 23 2010, 11:58 AM

^ agreed, the pan has definately been lifted by the pan and has most likely damaged the oil pick-up. This engine is probably already got spun bearings due to oil starvation.

This engine cradle and tranny adapter looks excellent. You could easily get a ez30r in there with it being less than an 1" longer than a ej257 ect. A built ej257 with a gt35r can crank out over 500 whp/wtq. Most builds are probably between 350-400 whp/wtq. If the porsche tranny can hold up to this, it sounds like one hellofa setup.

jw

Posted by: precisionchassis Aug 25 2010, 04:06 AM

Turbo and supporting pieces...

Posted by: Phoenix 914-6GT Aug 25 2010, 01:42 PM

Wow.... you do some very nice work and use choice colors. That green on the 914 is sweet .

I may be in touch in about a year as I have been thinking of getting a Boxter for a daily. Sounds like a good way to go since I already know the Suby engines.

Posted by: charliew Aug 26 2010, 03:44 PM

Twin scroll, will you be able to use a factory header? It also looks like the motor cradle will allow a fatter oil pan but with the stuff you are doing it will probably be a dry sump right?

Posted by: precisionchassis Aug 26 2010, 05:30 PM

I'm not going to be using the factory manifolds. The factory exhaust is designed to run along the right side of the motor which is where the Boxster has it's shifter cables and linkage. I will be making custom stainless steel headers that will dump into the turbo on the left side of the transaxle. I'll have some pictures up in a few days of the exhaust.

No dry sump on this car (too expensive to justify)

Posted by: precisionchassis Sep 2 2010, 02:33 AM

Started on the wiring harness tonight. Here is the unmolested 2007 WRX harness ready to be "reduced" wire by wire...

Posted by: precisionchassis Sep 3 2010, 07:59 PM

I finally got the exhaust finished today. I'm pretty happy with the way it came out. I still need to add two double slip joints in between the cylinder banks, some wastegate dump supports, and a couple of O2 bungs, but other than that, it's done. This first system is only 304 SS but I made sure to carefully purge everything, and all of the welds are full penetration welds rather than the standard "automotive style" welds so it will have the best possible chance of surviving. Also, the turbo is supported by a 1/4" thick plate bracket so the actual exhaust tubing isn't holding any weight other than it's own. If the 304 doesn't survive, then I will do the second set in 321 and see how long that lasts.

Posted by: Rotary'14 Sep 3 2010, 08:03 PM

That's a work of art. You do some awesome work. I love it and I don't even need it (yet).

-Robert

Posted by: charliew Sep 3 2010, 09:23 PM

The welds look good. Do you think the long tubes will hurt spool? And I wonder if water from the wheel will hurt the turbo housing.

Posted by: Andyrew Sep 3 2010, 10:31 PM

That is fuckin awesome...

Seriously.

Posted by: kg6dxn Sep 3 2010, 11:12 PM

Posted by: Britain Smith Sep 3 2010, 11:23 PM

That looks fantasic. Where did you get the flanges against the heads? I will be making my own custom header here soon.

-Britain

Posted by: precisionchassis Sep 4 2010, 09:37 AM

I'm not worried about lag in relation to header length. THe system is a little longer than the aftermarket Subie equal length headers, but not a whole lot longer once you take into consideration the length of the up-pipe. There's really no other place for the turbo to go in the chassis anyway. Besides, it worked on the 917/30 didn't it?



Water fron the wheel shouldn't be an issue since I will be retaining the rear wheel liners, and the fact that this car will be a track car.

Posted by: precisionchassis Sep 4 2010, 09:40 AM

I had my water jet guy cut the flanges from some 1/2" thick 305 SS. I had him do a few sets so I have some extras if you want. Send me a PM if you are interested. When I was looking around for some for myself, I had a hard time finding any that were thick enough, or had the right 1.755" holes for the tubing to slide into.

Posted by: bryanc Sep 4 2010, 10:04 AM

Sweet!!! Is that my old car? One of those tons of Boxsters with a bad motor?

Posted by: precisionchassis Sep 4 2010, 10:08 AM

Hahaha, yes it is. I'm breathing new life into it. I was going to have Jim tell you about but I wasn't sure if you were a "Porsche Purist" who would be offended by seeing it with something other than a Porshce motor in it

You should update your "signature" on the status of the car

Posted by: bryanc Sep 4 2010, 10:13 AM

I'll update the signature. I'm certainly no purist. If my time and budget allowed, the car would have gotten something interesting done to it--I was thinking an Audi V8 though....

Posted by: Zaney Sep 4 2010, 09:15 PM

Seeing that exhaust in front would blow a Porsche snobs mind!

Posted by: ottox914 Sep 5 2010, 06:58 AM

That exhaust system is just amazing. Between that and the trans adapter, hope you are making good notes because you could be making more adapters and exhaust systems...

With a properly sized turbo the tubes length should not be a problem. Check out the turbo location in my turbo project thread below. Water/turbo housing has been a non-issue as well.

Also google up STS turbo systems, they do rear mount turbos for many other cars, and while it may be a little unconventional, it can work well.

Posted by: Dr Evil Sep 5 2010, 08:44 AM

I am awed by this build. One thing that I notice, though, is that your popes are really close to the gear box. Typically this can led to premature wear and failure. Is this something that you already considered and have provided for?

Posted by: roadster fan Sep 5 2010, 02:37 PM

huh? I missed those guys in his pics is this like "where's waldo?"

Jim

Posted by: Dr Evil Sep 5 2010, 06:31 PM

Blah blah, I was typing on my iPod. It is not easy

Posted by: precisionchassis Sep 5 2010, 10:54 PM

To answer your question, Yes, I do plan on heat wrapping the entire system, and adding strategic heat shields where they are needed. Also, this car will have a transmission oil cooler (as all track cars should) so I'm not really concerned.

Posted by: precisionchassis Sep 5 2010, 10:55 PM

oh, and yes, I am keeping very detailed notes on everything. I'm not building this with the intentions of making a "one-off".

Posted by: ottox914 Sep 6 2010, 06:54 AM

I was noticing the same thing- maybe if/when this system proves itself durable they could be jet hot coated. Kind of a shame to hide that nice SS work, but I coated the 914T exhaust and it was a good thing for temp control under the car.

Posted by: precisionchassis Sep 9 2010, 05:37 PM

The wiring harness has been reduced to only what is needed to make the engine run.... hopefully.



And here's what wasn't used...

Posted by: precisionchassis Sep 14 2010, 02:39 AM

I got the first round of primer sprayed on the prototype fiberglass roof scoop. Once I'm happy with the shape and finish, I'll make a mold off of this part. The plan is to make the scoop removable so I can get to the rear trunk and remove the fiberglass hard top to get to the top of the engine. Also, now that most of the rear window will be blocked, I will probably just fill it in and mount a rear facing camera somewhere and an LCD display where the rear view mirror would go.

I know the shape of the scoop may not be the most attractive, but it will definetly serve it's purpose of getting a lot of cool air to the intercooler which will be in the rear trunk and will vent down over the transaxle and through the license plate are in the rear bumper.

Posted by: jimkelly Sep 14 2010, 06:33 AM

thanks for keepin the pics coming : )

Posted by: Britain Smith Sep 14 2010, 10:39 AM

Looks cool. Did you mold the whole thing or adapt it from something else? Any pictures of the process as you went?

-Britain

Posted by: precisionchassis Sep 14 2010, 01:22 PM

I made the whole thing from scratch. Cut and glued foam to the car, sculpted the foam in the shape I wanted, covered the body with mold release in the flange areas, fiberglassed over the foam, removed everything from the car and scraped the foam out. Then sanded the fiberglass, body worked it, and sprayed it with a primer filler. I'll probably block it one more time, touch up any low spots, primer it again, then final sand it before I make the mold. It's a lot of work for sure. I'll have about 35 hours into the prototype part.

Posted by: Britain Smith Sep 14 2010, 03:32 PM

Yep, been there, done that. It looks good though.

-Britain

Posted by: bryanc Oct 9 2010, 11:13 AM

Any updates???

Posted by: precisionchassis Nov 4 2010, 01:27 PM

Quick update...

The plan was to finish the intercooler plumbing before doing the cage to make things easier... but I couldn't help myself. The cage isn't done yet (still have harness bars to add and final welding) but it's pretty close. I'll throw up some better cage pictures once everything is completely finished...







I made a custom intercooler for the trunk and started the "duct-work" to direct the hot air out the rear bumper. The last shot shows the bottom of the duct open. This will be closed off to force the air out behind the car rather than randomly under the car. I'm just waiting to pull the engine/tranny to finish everything off. You can see the turbo dumps directly into the intercooler on the driver's side, then shoots off into the engine bay on the passenger side. The plumbing will be VERY short and direct. I was going to use Wiggins clamps, but then reminded myself that this is supposed to be a "budget build" The intercooler core measures 18" x 12" x 4.5" with 2.75" inlet/outlets

Posted by: Boxsterund914 Nov 10 2010, 03:34 PM

Are those rear flares something you made? If not, who did you source them from?

Posted by: precisionchassis Nov 10 2010, 03:49 PM

A.I.R. makes the flares, but I have to warn you... if you are used to the way the 914 and air cooled 911 flares are added, you will be amazed at how much more work it takes to do flares on the rear of a Boxster. It involved cutting the quarter panels (obviously) but you also have to reconstruct the inner wheel-well a bit because it will no longer extend all the way out to the flare, and you will be left with a large gap that would allow the inner quarter panel to fill up with road debris, water, or whatever. Also, to date, A.I.R. doesn't sell a flared rear bumper, so you have to bond the flare to both the quarter panel, and rear bumper, then cut the flare in two along the stock body line, then fiberglass new "flanges" on both the bumper piece, and quarter panel piece. In short, if you aren't comfortable with cutting, welding, sheetmetal fabrication, body work, and fiberglass work, you will have to pay the big $$$ to have it done by a shop.

Posted by: Hontec Nov 10 2010, 04:04 PM

Beautiful work!!!

Posted by: precisionchassis Nov 13 2010, 07:21 PM

Intercooler plumbing finished. That's it. Only one short section of tube on the cold side. The hot side is just a 2"-2.75" coupler from the turbo to the intercooler so no plumbing there. The engine and transmission are now out so I can do all of the engine service work (TGV delete, gaskets, injectors, fuel rails, leak-down test blah... blah...) and install the flywheel. The next time the engine goes in the chassis will be to try and start it. Time to finish the cage, do the body work, and paint the thing...

Posted by: precisionchassis Dec 2 2010, 08:01 PM

Air-Jacks added...

Posted by: Andyrew Dec 2 2010, 10:43 PM

Air jacks are so cool!

Posted by: geniusanthony Dec 3 2010, 01:06 AM

I think your doing a great job on this build. The cage work looks pretty amazing, one of the touches I like are the gussets on the door bars. What is the proper name for those chamfered holes in the gussets called and what tool do you make them with? Regarding the air duct, It looks like the area across the rear window gets much larger there. Of note is the cross section at the base of the rear window. If you wanted the regain some of your rear window use, what do you think would happen if you where to narrow that section at the window while maintaining the profile? Would not the velocity of the air remain higher and that being what cools the intercooler aid in heat dissipation?

Just some thoughts I had while reading, great project though, can't wait to see it come together.

Posted by: precisionchassis Dec 14 2010, 07:01 PM

So one of the things I have been dreading ever since I decided to run the wide body GT2 front end is the radiator duct situation. There are two ways to go about it, the expensive way, and the time consuming way. I chose the latter for two reasons. The first reason is the cost of converting the radiators and related duct work to the Turbo/GT2 spec. Basically, that would mean all three turbo 996 radiators, GT2 air ducts for all 3 radiators, radiator mounting brackets for all 3 radiators, and matching cooling lines along with other misc. hardware. Yeah, it's expensive... like a few thousand dollars. Not in the budget for this car. The other reason I decided to stick with the stock Boxster radiators is I want to be able to test the cooling capabilities of the stock Boxster cooling system with the extra horsepower and potential heat that the turbo motor might create. So here is what I came up with...








The side radiators are in the stock location using the stock mounting brackets. The center radiator mounts upside down using a slightly modified stock mounting bracket and the stock plastic duct. In stock configuration, the Boxster S and 996 radiator would vent down below the car through holes in the bottom of the bumper cover. Aerodynamically this is less than ideal which is why the GT3, RSR and GT2's vent up through a hole on the top of the bumper cover. What this means is I had to move the center radiator forward and angle it up to make room for some duct work that would direct the air up instead of down.

Posted by: precisionchassis Dec 30 2010, 03:46 AM

Plumbed the air-jacks and started on the electronic power steering conversion. Both are almost finished, just need to get a few more fittings.

Posted by: Jeroen Dec 30 2010, 08:22 AM

awesome fabwork (as usual)

Posted by: ottox914 Dec 30 2010, 08:47 PM

What you are creating is almost to awesome for words.

Posted by: precisionchassis Jan 12 2011, 07:18 PM

Added a rear wing...

Posted by: precisionchassis May 15 2011, 05:12 PM

Quick update with everything in primer. Just waiting on the wheels to be made so I can test-fit everything before I final sand and start painting everything.

Posted by: Scarlet75 May 15 2011, 05:21 PM

Maybe its just me but I dont see a 914 anywhere Perhaps the title should be changed to OT or SOT or WOT

Posted by: precisionchassis May 15 2011, 05:24 PM

6 pages in and nobody has complained yet... this engine/transaxle configuration would directly translate into 914 applications. If someone wants me to add "SOT" to the title a mod can let me know... or I can get rid of the thread all together...

Posted by: kg6dxn May 15 2011, 05:39 PM

You can edit your first post and change the tittle...

Posted by: BIGKAT_83 May 15 2011, 07:34 PM

That thing is looking great..... Have you got the adapter completed yet.
Its got me looking for a boxster to do the conversion too.

Posted by: precisionchassis May 15 2011, 08:52 PM

Yes, the adapter kit is finished, just need to test it.

Posted by: firstknight13 May 17 2011, 07:49 PM

i have both the engine and the 5 speed.......how much for the adapter plate?? im sure the line is long

Posted by: Loser_Cruiser May 18 2011, 01:44 PM

This is awesome, good thing I didn't see this befor I bought my 3.6 and conversion stuff.

Posted by: enderw88 May 23 2011, 02:46 PM

Does anyone know if the boxster transmission will mate to the older aircooled porsche engines? This seem like a good upgrade for large -6 conversions.

Posted by: rohar May 23 2011, 02:49 PM

No, it won't. The bellhousing's all wrong (bolts in different places) and the starter is on the engine side rather than the tranny side which makes it that much more difficult. Then, the output flanges are all kinds of different with an offset pumpkin so there's that.

Posted by: enderw88 May 23 2011, 03:30 PM

Thanks, once I figured out how to more effectively search I found all the threads. Of course I had to post the question before I copped a clue...

Posted by: precisionchassis Jun 10 2011, 02:24 AM

Some suspension bits...




Control arms with some of those pieces installed. There won't be a single rubber bushing anywhere on the car. Everything is mono-ball or solid.



Been making some good progress lately. The wheels came in so I was able to mount some NT01's on them and make the car a roller (temporarily) to verify tire/wheel fitment with the quarter panels and suspension. I need to add some 8mm spacers on the rear so I can lower the back end of the car to a more appropriate ride height, but otherwise everything fits great so the next step is to start painting stuff.

Here is a teaser pic of the car on the ground for the first time in almost a year, and the Racepak dash that I mounted in place of the stock gauge pod.

Posted by: banksyinoz Jun 10 2011, 03:33 AM

matt green or orange ??

Posted by: Jeroen Jun 10 2011, 07:41 AM

sweet!
no GT3 arms?

Posted by: precisionchassis Jun 10 2011, 08:34 AM

Nope. I was able to accomplish the same thing for less money use the Tarett parts and camber plates.

It will be painted bright green.

Posted by: matthepcat Jun 10 2011, 09:45 AM

What wheels are those?

Posted by: precisionchassis Jun 10 2011, 02:53 PM

CCW Classics in 17x10 and 17x12 with 315/35/17 rears and 275/40/17 in front.

Posted by: precisionchassis Jun 22 2011, 01:08 AM

Finally started the paint process.

Posted by: Britain Smith Jun 22 2011, 09:29 AM

Holy Green Batman!

Posted by: tavoman27 Jun 22 2011, 10:18 AM

The Gt3 arms are good for upgrades on BSR or boxter specs because they can not use camber plates so by using the GT3 arms and some shim plates the can work on lowering the car and camber/alignment... now this car is not a spec vehicle so he can use more suspension components up on top (camber plates) and accomplish the same as with the gt3 arms.... nice ride!!!! and he was not kidding about being bright green!!!! hahahaha

Posted by: precisionchassis Jul 15 2011, 09:29 PM

Exterior is now 90% finished. Just need to finish up a few small details...












Engine and transaxle install is next...

Posted by: BKLA Jul 15 2011, 11:47 PM

Beautiful work!!!!

Posted by: precisionchassis Jul 17 2011, 10:45 AM

Posted by: Jeroen Jul 17 2011, 11:02 AM

read on a website somewhere that you're gonna do a mid engined 356?
can you keep us posted on that as well?

Posted by: precisionchassis Jul 17 2011, 12:38 PM

Lol! Yes I am... I guess there are no secrets on the interwebz its a RHD "A" so I'm. Sure I'll piss off some Porsche nuts

Posted by: precisionchassis Aug 1 2011, 03:43 PM

I've been working on the final assembly lately. It's basically down to some fluid plumbing (accusump, oil coolers, scavange pump etc) and finishing up the chassis harness and then I should be able to try and fire the motor. The air jacks work though...

Posted by: Andyrew Aug 1 2011, 10:18 PM

Wow that looks amazing! Great work!!

Posted by: Randal Aug 1 2011, 10:49 PM

So much for great engineering. LMAO!

Posted by: Randal Aug 1 2011, 10:52 PM

Absolutely beautiful work.

Love to be sitting in that machine your first time on the track!

Posted by: JRust Aug 2 2011, 12:02 AM

So what is the adapter plate going to run? Found a decent deal on a 99 Boxter tranny. It is complete from the shifter back. While I do plan on doing a suby conversion. It would be of more use in my v8 conversion that is almost road worthy. I do want to know for my suby though

Just wish there was an option for the boxter tranny with my v8. I need to look into it more I guess . Probably is an option out there somewhere

Posted by: jcambo7 Aug 2 2011, 12:46 AM

This Boxter is awesome. Those flares and all the other mods are sweet. What is the plan for the car?

Posted by: precisionchassis Aug 2 2011, 01:24 AM

I wouldn't put a V8 in front of the 5 speed Boxster tranny, only the 6 speed. If you are going to use a V8, the only real choice is an LSx motor. For that application, KEP will make you an adapter kit for around $2000 last time I checked and from what they told me, it's something like 4" thick There have been other people who were supposedly working on another LSx/Boxster based conversion kit, but to my knowledge, it hasn't actually happened yet. I know there was a shop in TX I think that was advertising a conversion kit for the LSx too but I've never seen a finished product. Ultima is offering an inverted 996 gearbox (same as Boxster 6 speed) so that means they have done it, but it would require running an inverted rear engine box.

If you want to use the 5 speed, the Subie motor would be ideal as it doesn't make the kind of gearbox killing torque that the V8's make. Although people use 901's in their V8 cars so I guess it's possible.

I'm not going to be talking "prices" on here because I'm not a paid vendor and it wouldn't be fair.

Posted by: precisionchassis Aug 2 2011, 01:26 AM

To test the conversion parts and win races...

Posted by: Amenson Aug 2 2011, 10:23 AM

With whom would it be fair to discuss prices?

Posted by: precisionchassis Sep 24 2011, 03:43 PM

Wiring is DONE! Other than the ABS system, the chassis harness was built from scratch. The engine management is stock from the 2007 WRX donor and fit in the stock Boxster location using all stock mounting points. We were even able to use the stock Porsche ECU mounting studs with the stock Subaru ECU and relays. Everything powers up and the engine cranks. Still need to plumb the oil system, fuel system, and cooling system, but then we should be able to fire it up and get it on the dyno for some tuning.


Rear trunk








Accu Sump

Posted by: precisionchassis Oct 14 2011, 08:21 PM

http://www.youtube.com/watch?v=SwLKsEqj8ZQ

Posted by: dw914er Oct 14 2011, 09:31 PM

EJ255? I love the sound of a ball bearing twin scroll turbo after you shut the car off


Great work! The Turbo EJ's are definitely a sweet motor.

Posted by: 76-914 Oct 15 2011, 10:51 PM

Most Excellant

Posted by: partwerks Oct 15 2011, 11:36 PM

Will this 5 or 6 speed work with the EJ20 engine? If so, would it shift with a cable?

Posted by: precisionchassis Oct 16 2011, 12:38 AM

The same kit would work with any EJ, EG, or EZ Subaru motor. The Boxster Transaxle is designed to be cable shifted.

Posted by: Cairo94507 Oct 16 2011, 07:41 AM

Holy crap! That is just an insane build with skills off the planet.

Posted by: partwerks Oct 16 2011, 10:15 AM

I wonder if the cable shifter I currently have/got from cable shift.com will work with this trans?

I would imagine that this trans doesn't have all the issues with trying to get it in gear, finding gears and get it in gear when at a standstill, etc.?

Posted by: precisionchassis Oct 16 2011, 11:49 AM

No issues at all with finding gears or trying to get into gear. It shifts like modern car... very "Honda" like. I'm sure you could easily adapt the shifter you have to work on the transaxle end. The other option is to use a stock Boxster/996 style shifter. They are very "Universal" in the way they mount to the car and are VERY cheap to buy

Posted by: partwerks Oct 16 2011, 09:09 PM

I'm wondering what all has to be changed to use this trans as I have a tubular cradle that the engine sits in from Renegade Hybrids. I realize the cables may have to be altered a bit, but what other unseen things are there or is it plug N play?

What is the cost of the 5 speed vs 6 speed?

Posted by: SCV Oct 16 2011, 09:37 PM

That is simply fantastic work, and the color is most appropriate. By all means, carry on.

Posted by: precisionchassis Nov 1 2011, 03:20 PM

We are also using this car to test out a few non-conversion related products including a programmable brake light flasher module. With this module, we are able to set the brake lights to activate with an adjustable number of flashes prior to constant illumination, adjust the flash frequency (faster flashing available with LED bulbs). This is something we are developing specifically for full size cars and is not just a retrofitted motorcycle flasher unit.

http://www.youtube.com/watch?v=Y3doLgSISDo&feature=feedu

Posted by: grantsfo Nov 1 2011, 03:26 PM

Awesome as usual!

Posted by: jmill Nov 1 2011, 03:48 PM

Beautiful work. I hate to say that color reminds me of the Lotus in "The Rookie."




Attached image(s)

Posted by: precisionchassis Nov 1 2011, 03:56 PM

Funny you should mention that. The color is based on the Lotus "Krypton Green" minus the pearl.

Posted by: precisionchassis Nov 12 2011, 02:19 PM

Finally, all of the plumbing is finished, communication for the Racepak dash is finalized and programmed, and it's ready for a tune. More video coming soon...

Posted by: kg6dxn Nov 12 2011, 02:48 PM

Wow!

Posted by: 76-914 Nov 12 2011, 05:51 PM

And it's beginning to feel like having a crush on a hot movie star. Why, when it's unobtainium for me. Damn beautiful and fantastic craftsmanship. Will there be plans or kits for a basic drivetrain

Posted by: precisionchassis Nov 12 2011, 05:56 PM

The plan is to have basic kits first, which will include a custom flywheel, adapter plate, clutch kit, starter motor and engine cradle for both Boxster and 914 chassis

Posted by: moparrob Nov 12 2011, 07:40 PM

Amazingly high quality. Great work and a pleasure to follow. You certainly have raised the bar for fit and finish.

Posted by: partwerks Nov 12 2011, 07:54 PM

What kind of coinage are we talking here for everything it takes to make it go down the road?

Posted by: precisionchassis Nov 12 2011, 08:01 PM

That's a loaded question. There are a million different ways to do the same conversion as far as exhaust, intake (or intercooler), turbo, headers... I can tell you how much the basic components will cost but after that it will depend largely on how you equip it and what your goals are. PM me for some specific pricing. The biggest hurdle for 914 guys will be switching the clutch over to hydraulic actuation instead of cable but anyone who has ever driver a Boxster or newer water cooled Porsche knows how well these transaxles shift.

Posted by: precisionchassis Jan 20 2012, 11:50 AM

So we took the car to UMS Tuning to take care of the tuning. Tony worked his magic and the car made 416whp at 17.75lbs of boost. Considering the application of the car (road racing) we pulled a bit timing just to play it safe and ended up at 396whp and 354 ft/lb. Should be plenty of power for a 2400lb car. Dyno video link at bottom. Sound quality questionable...




http://www.youtube.com/watch?v=TDAWLgdfk40

Posted by: Andyrew Jan 20 2012, 12:15 PM

At only 18lbs of boost thats pretty good! Congrats!! What gas?

Posted by: BKLA Jan 20 2012, 12:26 PM

Very cool! (But it sounds like a hot rod type IV!!!!)

Posted by: precisionchassis Jan 20 2012, 12:29 PM

110 race fuel. Trying to give the stock pistons a fighting chance.

Posted by: a914622 Jan 20 2012, 11:49 PM

Bumping the 400 at the wheels those pistons are going to need race gas and no miss shifts

Posted by: precisionchassis Feb 6 2012, 04:14 PM

Here are some pictures and an in-car video. No blazing fast lap times this time out. I'm still a bit rusty because I haven't driven on track in almost 3 years, and the car has only been completed for 12 hours at this point. There is a lot of speed potential in the car (more than my driving ability could use this past weekend) and I can't wait to see how it fairs against other cars in it's class after we get some development time under our belts.






VIDEO!
http://youtu.be/iwyKeSLCuiU

And for anyone who was wondering if the Boxster cooling system could handle the cooling needs of the Subaru turbo engine... this is what we had to do just to get the car to run at normal operating temps. This was with a restrictor plate in place of the functioning thermostat. We are going to have to go back to a thermostat. Without any tape on the front end, the water temps never got above 125 degrees while driving.

Posted by: firstknight13 Feb 6 2012, 11:18 PM

so are you selling the adapter??? yes or no???....thanks

Posted by: precisionchassis Feb 7 2012, 12:07 AM

Yes

Posted by: 76-914 Feb 7 2012, 12:57 PM

After you get all the "bugs" worked out maybe you can post "some" anticipated kit costs. Thx for sharing.

Posted by: precisionchassis Feb 7 2012, 01:04 PM

I already have some of this figured out. Email me for more info.

Posted by: firstknight13 Feb 7 2012, 04:35 PM

ok how much....details please...thanks

Posted by: precisionchassis Feb 7 2012, 11:58 PM

send me an email.

Posted by: partwerks Sep 3 2022, 09:49 PM

Do you make an adapter plate that will work with say, a Subaru EZ30D, or WRX-STI, and mate up with a 2001 Boxster 986-5 speed transaxle?