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 Porsche Boxster S 986 - Audi 2.7 Bi-Turbo engine swap View next topic
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Tue Jan 19, 2016 11:20 pm  Reply with quoteBack to top

Cheers guys, i'm getting excited now things are moving along

I've made a decision on the turbo. Have gone for a big single Holset. It's a hybrid, HX40 compressor and HX35 12cm (ar 0.85) turbine. I've read a lot of good things about Holsets, they apparently spool faster than the equivalent Garrett, It's capable of 650+bhp. I wanted a turbo with a bit of room left in it so i'm not hammering it past it's peak efficiency to make decent power and having temperature control problems.

When it turns up i'll get a few photos.
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jockthedog
Experienced


Car: S4-B5.3
Power: C5-RS6Plus
Torque: in' hell!
Engine code: 0xFA

Joined: 14 Mar 2011
Posts: 3129

Location: Moonbase Alpha

PostPosted: Tue Jan 19, 2016 11:23 pm Reply with quoteBack to top

Hmmmm like the idea and admire your ambition but what is this gonna do to the weight distribution in the car?
Isn't this lump much heavier and that weight is higher up too?

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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Tue Jan 19, 2016 11:49 pm Reply with quoteBack to top

I don't think there will be that much difference in weight, the Boxster engine is a big heavy lump. It'd be surprised if there is a noticeable difference in handling. I have to say, i'm not really concerned anyway. The chassis is such a good starting point. I've ordered some coilovers for it today which have adjustable damping, i'll be fitting an LSD also, I think it'll be able to out handle a standard Boxster S once it's all set-up.
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BennyBoo
Expert


Car: B5 S4 Saloon
Power: Not Enough
Torque: Not Enough
Engine code: AGB

Joined: 12 Mar 2010
Posts: 5702

Location: Grimsby, UK

PostPosted: Wed Jan 20, 2016 12:06 am Reply with quoteBack to top

jockthedog wrote:
Hmmmm like the idea and admire your ambition but what is this gonna do to the weight distribution in the car?
Isn't this lump much heavier and that weight is higher up too?


I bet they weight in about the same.. The boxer is a 2.7 6 cylinder too..?

What does the S4 engine weigh in at, 200kg?

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In Progress:
Twin Audi K24, HardKnockSpeedShop Custom Manifolds 2.4 heads, 2.8 Cams, RS4 Rods, External W/G's + Screamers, True Dual 2.5" straight pipes
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Wed Jan 20, 2016 12:18 am Reply with quoteBack to top

Mine was a 3.2. It's wider and longer than the V6. I can't see the fact the cylinder heads being a foot higher up will make a huge difference although  I'm adding extra weight with the turbo and charge cooler systems.
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Kent
Skilled



Joined: 22 Sep 2012
Posts: 1735


PostPosted: Wed Jan 20, 2016 2:31 am Reply with quoteBack to top

Its splitting hairs when one car will be able to smash the absolute pony out of the other when changing velocity

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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Thu Jan 28, 2016 8:44 pm Reply with quoteBack to top

The Holset arrived. That's a K03 next to it. It's pretty big but it'll fit where I want (near the alternator)

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Scottieb5s4
Brand New, Welcome :)


Car: B5 s4 avant
Power: Unknown
Torque: Unknown

Joined: 28 Jan 2016
Posts: 23

Location: West Yorkshire

PostPosted: Sat Jan 30, 2016 9:00 pm Reply with quoteBack to top

Liking the build this will be cool. I'm swapping my current single turbo to a holset too same as yours had it sat collecting dust not had chance to get it fitted yet need to swap the vband on the down pipe
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Sun Jan 31, 2016 11:40 am Reply with quoteBack to top

I had a quick look at your pictures, the single turbo looks good. If you get the Holset fitted before I finish my build, it'd be interested in how it performs.
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CliveH
Expert


Car: B8 S4 avant
Power: MRC Stage2
Torque: MRC Stage2
Engine code: CAKA

Joined: 10 May 2008
Posts: 4089

Location: Leeds

PostPosted: Sun Jan 31, 2016 11:59 am Reply with quoteBack to top

Wow!

When I read the first post, I thought there's no way that this will work out, but hats off to you this is some project!

My only question now, having seen how far you've got, is how and where are you going to locate the sizeable intercooler needed to deal with this setup?

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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Sun Jan 31, 2016 12:38 pm Reply with quoteBack to top

I'm going to run a charge cooler setup. I will mount the core in the engine bay on the opposite side to the turbo. I'll run the radiator in the front bumper. The Boxster has 3 rads so I might use the center one for the charge cooler and see how the engine temperatures are. If the 2 side radiators can't cope i'll see about adding an extra radiator. Some 911's and the later Cayman S's don't have the extra center radiator, i'm not sure why the Boxster S does.  I'll run the water tank (quite a large one to add capacity to the system) in the boot. I've not decided if it'll be the front or rear boot yet.
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Scottieb5s4
Brand New, Welcome :)


Car: B5 s4 avant
Power: Unknown
Torque: Unknown

Joined: 28 Jan 2016
Posts: 23

Location: West Yorkshire

PostPosted: Sun Jan 31, 2016 12:52 pm Reply with quoteBack to top

Escy wrote:
I had a quick look at your pictures, the single turbo looks good. If you get the Holset fitted before I finish my build, it'd be interested in how it performs.

Should be going on within the next month hopefully. My current turbo hits full boost by about 3800rpm and the holset should have less lag than the one that's on I'll update on how it performs can only be better
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Wed Feb 10, 2016 2:34 am Reply with quoteBack to top

Little update.

This weekend I finished up the engine mounts, the engine is now bolted into the chassis. I'm using the standard Boxster engine mount locations, i've cut and re-welded the gearbox mounts (as the gearbox has moved forward an inch) and made a cradle that bolts to the original V6 engine mount brackets and it ties into the front of the engine where the original snub mount was bolted. The standard Boxster mount then bolts to this cradle. The picture shows it mounted to my 2.4 block that I bought for the cylinder heads, it came in handy for mocking this up. 



I was having some problems with driveshaft clearance, with the wheels off the ground the driveshafts were resting on the lower suspension arm mount. I knew coilovers would solve this as they have a shorter body so the hub wouldn't drop as much. I hadn't originally planned on coilovers, it was something i'd look at once it was up running so I was mindful about blowing the budget and leaving myself short in other areas. There aren't many options around for Boxsters that's reasonable money. You got the cheap and nasty £350 ones on ebay otherwise it's over £1000 for a set. After trawling the internet I came across some made by Yellow Speed Racing, i'm also into my Jap cars and knew their coilovers have a good reputation. They have adjustable top mounts and adjustable damping which will help me get it set-up nicely since i'm messing with the weight distribution. They seemed like very good value for £700 so that's what I went with. 

I fitted a rear shock this evening to have a quick look, i've now got loads more space under the driveshaft which has solved the clearance issue and also given me tons more space for running the exhaust which is going to be very useful.





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Kent
Skilled



Joined: 22 Sep 2012
Posts: 1735


PostPosted: Wed Feb 10, 2016 8:59 am Reply with quoteBack to top

loving this

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coullstar
Experienced



Joined: 20 Jan 2012
Posts: 3260

Location: Aberdeen

PostPosted: Wed Feb 10, 2016 10:02 am Reply with quoteBack to top

This is going to be a bit of an animal.  Best thing is the noise will be there right behind you. Are you mapping it?  Some progressive boost would be good.

My 996 only has two rads at the front (albeit the turbo ones so don't know if there bigger) but I have seen people adding a third or there from factory on tip models I think.

Do you have AC condensors?  Just thinking you could maybe ditch the AC system which would then expose the rads a bit more to airflow then you can use the front as a chargecooler.  If it gets hot put the roof down!!

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