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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: Fri Aug 11, 2017 11:16 pm  Reply with quoteBack to top

Thank you for all the kind words guys, i'm feeling so low at the moment, they do help.  

mrgristle wrote:
Have you considered putting up a fundraiser page to start another project or at least recoup some of the costs?


This is something a mate and my brother suggested after having seen similar things on forums before. The thing is, even if people wanted to chip in some money I don't know what the aim would be? I'd like to re-build it, most of the important bits seem to have survived but the target to raise would be too high I think. Boxster's start at around 3k.
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Sat Aug 12, 2017 3:01 am Reply with quoteBack to top

- edit, the pictures are all random sizes, I don't know why. Can something be done about it?

The Salvage Operation

I went to the salvage yard first thing Monday morning to see what I was left with, it was a right mess. I had a good look and I decided there was enough salvageable parts to be worth getting it back. The recovery from the A470 after it burned out cost me £250. That was a nice kick in the b*llocks.







Due to the state of it, getting it back was a problem, the salvage yard could take it on a hiab for me but their driver was ill so they couldnít give me a day and they charge £20 a day storage so I didnít fancy being left in limbo. They also wanted £120 to take it to my house which was only about 10 miles. Didnít fancy giving them more money.

There is a local guy Jamie (Prestige Transport and Recovery) who I usually use whenever I need something moving, he's good. I sent him a picture on the off chance heíd fancy it, fully expecting him to tell me no way. As we are friends on Facebook heís knew about my Porsche build so I think he wanted to try and help me out (against his better judgement). He said heíd have a crack at it.

We did it Wednesday. I got the day off work and wanted to get it moved and completely stripped in one day so the shell can be collected quickly. My mate, Adam also took a day off work to help me which was really nice of him Ė Iím really lucky to have a friend like that. As it turned out I had no chance of doing it without him.

The salvage yard were able to load the car with a forklift so that side was drama free.





Getting it off wasn't drama free. First I had to get under it to cut the handbrake cables and then we used my engine hoist to raise the front end so it cleared the truck bed and Jamie winched it down slowly, we were on a hill so it was pretty hairy. I think there were a few times where Jamie was wondering what he'd got himself into. As we were unloading, the guy from the car sales place near me who had seen it Sunday morning (and asked if Iíd sell it) drove past. His eyes popped out of his head when he saw it. After telling him all about it I asked him if heíd give us a hand, he obliged and ended up staying over an hour which Iím very grateful for. Iíve also got a neighbour thatís been following the build, heís building a house on his land so had a few guys working there, they all came around so there was 9 of us in total. I was really lucky to get so many people helping, as it was a nightmare. We dragged it up the hill and into the driveway with a combination of brute force, hoisting, jacking and winching. A wheel snapped on the engine hoist which made things more complicated, I abuse that hoist. I was very lucky to have the help I got.




Once it was on the drive Adam and I set about stripping it. That was pretty soul destroying. Two years to build and 6 hours to strip. We were wearing masks and gloves as its really unpleasant working on a fire damaged car, everything stinks. It was sketchy as hell getting the engine out, we were lifting the shell up with the wounded engine hoist and as we were on slope the engine wasnít easy to manoeuvre, it was deciding which way it wanted to go. We got it all stripped in the end but it was a hard day both emotionally and physically. My eyes in the first picture tell the story.










Looking at whatís been recovered, itís maybe not as bad as I initially thought. The parts I made for the conversion (exhaust, brackets, engine cradle) have all survived. There is oil in the sump still so Iím holding out hope the bottom end is ok. The engine looks a mess but the majority of the parts could be sourced from a naturally aspirated V6 for cheap (I think the 2.4 I bought at the start of the thread was £150 delivered). The flywheel, clutch and gearbox are ok. The driveshafts need new CV boots but are otherwise ok. I was holding out hope the ECU would have survived but itís ruined. I was confident the turbo would be fine so was a bit gutted to find the compressor wheel is damaged (couple of blades have rounded tips). The K&N had a big hole in it and you can see the crap the turbo sucked up so my theory is perhaps the fire started earlier than when I first noticed a problem and the flames were being blown backwards by the wind which burnt the air filter, otherwise Iím not sure how the turbo would get damaged. I think the turbine wheel is ok so it shouldnít be an expensive re-build. The charge cooler core, tank and pump are ok. The wastegate is untouched.




Iím not sure where I go from here but Iíd like to think itíll all be able to live in a Boxster again rather than split it all up.

I think this picture is quite cool, might try and keep the badge if I can get it off.

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guymcc
Expert


Car: Misano RS4 B5
Power: 504ps
Torque: 604nm

Joined: 03 Jul 2010
Posts: 4659

Location: Aberdeenshire

PostPosted: Sat Aug 12, 2017 7:08 am Reply with quoteBack to top

Absolutely gutted for you mate!!!!  Really bad luck, and I hope you eventually get things going again in another shell.  Glad you and your daughter are ok though.  Some quick thinking at the road side , fair play.

All the best going forward

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Pearl white 20v ur quattro - mmmm!
Daily mk5 gt tdi pd170
Audi 80 B4 avant alpine white!- Sold
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Red S3 - Sold
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English Expat
Learning



Joined: 09 Jul 2016
Posts: 90

Location: The Netherlands

PostPosted: Sat Aug 12, 2017 12:55 pm Reply with quoteBack to top

Get a crowd funding page going. I will happily contribute to it and I really think that you will soon have enough for the next boxster.  Tough day for you but well done for not giving up.
As before, I am looking forward to the next update!

Finally, as everyone else has said, best bit is you are both ok.
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Ian_C
Experienced



Joined: 26 Feb 2011
Posts: 2937

Location: Bedford

PostPosted: Sat Aug 12, 2017 1:55 pm Reply with quoteBack to top

Very very sad to read.  Just glad you and your daughter are okay, and that you rescued her teddy, she would never have forgiven you if you hadn't!

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B6 S4 Avant gone but never ever forgotten
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jimbo
GM Auto Services


Car: blue
Power: 597whp
Torque: 693lbft

Joined: 24 Apr 2008
Posts: 11444


PostPosted: Sat Aug 12, 2017 2:34 pm Reply with quoteBack to top

Ive got a selection of engine rubber and plastic parts ill happily give you to help get the lump looking how it should again  

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millions more parts on the shelf....

http://www.youtube.com/watch?v=_Ex6Q8fkdJk&feature=related
http://www.youtube.com/watch?v=xdNwmSu12_Q&feature=youtu.be
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Burnzybubbles
knowledgeable


Car: 98 Noggy b5 s4

Joined: 29 Apr 2016
Posts: 824


PostPosted: Sat Aug 12, 2017 2:42 pm Reply with quoteBack to top

What was the cause? Initial thoughts for me was fuel as you said you heard hissing, such a shame, makes me realise I may buy a proper sized extinguisher as from your unfortunate experience, it shows that the small ones aren't worth the bother 😩

Do you reckon if you had a full size extinguisher it would of saved the car? I know hindsight is wonderful but just from a perspective of maybe saving someone else's project in the future.

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Burnzybubbles
knowledgeable


Car: 98 Noggy b5 s4

Joined: 29 Apr 2016
Posts: 824


PostPosted: Sat Aug 12, 2017 2:43 pm Reply with quoteBack to top

Don't the alloys of the engine suffer really badly from fire damage?

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Blairz25
knowledgeable


Car: 2002 RS4 B5
Power: 420

Joined: 09 May 2015
Posts: 485

Location: Derbyshire

PostPosted: Sat Aug 12, 2017 6:24 pm Reply with quoteBack to top

Was reading this last night, expecting a video off the car on a run the way things were being explained, then I saw what happened...

I like many have been following this build from the start, very impressive build.

Such a shame, BUTTT you and your daughter are ok, that's the main thing, bit shocking it took 15 minutes for the fire engine, luckily you were both out off the car readily as it could have been a different story...

Salvage what you can mate, and try again, yea your right boxsters are around 3k ish, I did see this that I had spotted on eBay item num 122637479733 he said 3k is what he's after, well that's his reserve anyway.

Gutted for you mate, but main thing is your both ok.. chin up mate
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Phil_R
Brand New, Welcome :)


Car: A4 B5 4.2 V8
Power: 296 bhp
Torque: 295 lb/ft

Joined: 06 Jul 2015
Posts: 23

Location: Shropshire

PostPosted: Sat Aug 12, 2017 8:28 pm Reply with quoteBack to top

Gutted to see this as it was a great project but as everyone has said a car can be replaced, you got yourself and your daughter out and safe.

I do have an Ecumaster EMU sat here which would be a lot cheaper than getting a new one if you want to keep the same as before. I'm sure you will need time to think what you want to do but get in touch if you're interested.
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coullstar
Experienced



Joined: 20 Jan 2012
Posts: 3260

Location: Aberdeen

PostPosted: Sun Aug 13, 2017 9:15 am Reply with quoteBack to top

Holy moly gutting at this stage but main thing is you and your daughter are fine.

You get a cat d boxster for low money so I wouldn't say lol is lost.

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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Sun Aug 13, 2017 1:44 pm Reply with quoteBack to top

Blairz25 wrote:

Salvage what you can mate, and try again, yea your right boxsters are around 3k ish, I did see this that I had spotted on eBay item num 122637479733 he said 3k is what he's after, well that's his reserve anyway.


I did see that, it looks ripe for an engine conversion.

Burnzybubbles wrote:
What was the cause? Initial thoughts for me was fuel as you said you heard hissing, such a shame, makes me realise I may buy a proper sized extinguisher as from your unfortunate experience, it shows that the small ones aren't worth the bother 😩

Do you reckon if you had a full size extinguisher it would of saved the car? I know hindsight is wonderful but just from a perspective of maybe saving someone else's project in the future.


I think the problem with an engine bay fire on a Boxster is access. I was lying on the floor aiming upwards to the flames I could see, I think it was probably just the exhaust wrap soaked in either fuel or oil. To stand a fighting chance in that car it'd need a motorsport style fire suppression system with nozzles placed at the top of the engine bay.

I'm not sure about the cause of the fire, the oil pressure dropped which initially made me think it was that. After looking at the turbo I think maybe the fire started before that and perhaps the oil pressure drop was a result of the fire rather than the cause. The fuel pressure was constant but perhaps the leak was small and the pump had no problem maintaining the pressure even with a leak? I don't know.

Phil_R wrote:

I do have an Ecumaster EMU sat here which would be a lot cheaper than getting a new one if you want to keep the same as before. I'm sure you will need time to think what you want to do but get in touch if you're interested.


If I could get it off the ground again i'd look for the same ECU to keep it easy so i'll bear it in mind. I think maybe my dbw and canbus units will be ok with a few repairs.

Burnzybubbles wrote:
Don't the alloys of the engine suffer really badly from fire damage?


If anyone has any advice on this subject i'm all ears. I'd look to replace lots of parts from the engine rather than save them.

jimbo wrote:
Ive got a selection of engine rubber and plastic parts ill happily give you to help get the lump looking how it should again †


Thank you, that's very kind of you. I'll strip it down and see where i'm at with it.

A few people have mentioned about contributing to a fund to get the project going again. Some of the guy's on Pistonheads where I have a copy of this build thread running have set one up so if anyone does want to chip in here is a link. I've been humbled by the support, both the donations and the kind words from people.

https://www.pistonheads.com/gassi...ic.asp?h=0&f=47&t=1690014
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Wed Aug 16, 2017 6:16 pm Reply with quoteBack to top

Thank you everyone for the generous donations. The ball is rolling again. I won an auction for a ropey looking A6 that's got the all important 2.7t engine. Only done 125k which is pretty low for one of these. Not sure what the plan will be yet, either use bits from this to build mine back up or just use this one. I'll make that decision when I start stripping my crispy one down. I'll break it for parts so it should hopefully make a few quid back for the kitty to put towards a Boxster.  



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English Expat
Learning



Joined: 09 Jul 2016
Posts: 90

Location: The Netherlands

PostPosted: Thu Aug 17, 2017 2:19 pm Reply with quoteBack to top

Fantastic, I truly can't wait for the resurrection! May I suggest the title of the thread is changed to project Phoenix.

Great to see you are back on the project
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Thu Aug 17, 2017 11:29 pm Reply with quoteBack to top

Ha ha, good idea.
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