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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: Wed Feb 10, 2016 10:23 am  Reply with quoteBack to top

I can't wait to hear it, they are a great sounding engine.

Me and a mate are going to map it.

I'm in 2 minds about the air conditioning, i'd like the keep it but like you say, it'll impact on the engine radiators efficency. I need to replace an a/c pipe that runs the length of the car as it's been dented, plus there was no gas in the system when I pulled the old engine so it might be an issue somewhere else. It probably makes sense to ditch it, like you say, I can always put the roof down.
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Thu Feb 18, 2016 11:19 pm Reply with quoteBack to top

I'm going to make a start on the exhaust this weekend. I've decided on the position for the turbo, i'm going to bolt it to the back of the gearbox.




I've bought a load of bits. I'm wanting to be 550bhp give or take. With the turbo being far back in the exhaust system I wasn't sure exactly what size pipe work to go with. I've decided on 2.25" from the manifolds to the Y-piece (which i'll be cutting out of that Skyline twin downpipe). That then becomes 3" feeding into the turbo. It's a bit of a punt size wise as I realise the bigger the bore is pre-turbo the longer the pipe run is, the more energy is lost. I plan the wrap the whole system to keep to try and improve this. Opinions are welcome.

The exhaust housing has a 2.5" v-band and i'm stepping that up to a 3.5" system for the rest of the exhaust. I'll be running an external wastegate that vents to the atmosphere rather than back into the exhaust so that might end up making the post turbo exhaust equivalent to a 4" system.  I'm half considering  just having a 90 degree bend after the turbo and it  coming straight out of the middle of the bumper (in the standard Boxster location). It might be really loud as there wouldn't be any silencers in the system but the turbo itself might go someway to acting like a silencer. My other option would be to add a silencer and have the exhaust exit offset (on the drivers side) how most cars are, I prefer this as I think the center exit on the Boxster looks toss, especially if I run a single pipe rather than a dual, but i'd be left with a cutout in the bumper for the center exit which might look silly.


I might make a seperate thread for this as I don't know how many people will look in here. My compressor inlet is 4", can I use a 4" maf housing and adjust the ECU to read it correctly?

http://www.ebay.co.uk/itm/4-OD-10...item3cf73032f7:g:H3kAAOxy3cJTfjTL
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buzzard
Experienced


Car: B8 S4 gone

Joined: 23 Apr 2008
Posts: 3325


PostPosted: Thu Feb 18, 2016 11:27 pm Reply with quoteBack to top

That's one big momma of a turbo
Great project and really enjoying the build thread

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coullstar
Experienced



Joined: 20 Jan 2012
Posts: 3260

Location: Aberdeen

PostPosted: Fri Feb 19, 2016 7:22 am Reply with quoteBack to top

There is a guy over on 911uk forum that's building a rallycross boxster with a 2.7t but he is keeping the TT set up.

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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Fri Feb 19, 2016 8:46 am Reply with quoteBack to top

Thanks Buzzard, i'm also enjoying the build.

Coullstar, i'm following that build on Facebook. It's a cool build. I initially thought it'd be a useful resource for my project and I was speaking to Rob about it but our builds are so different, it's literally just the engine choice that's the same, nothing else is.
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Tue Feb 23, 2016 12:12 am Reply with quoteBack to top



This weekend I started the exhaust. I also made a bracket to mount the turbo off the back of the transaxle. My original plan was to have the car looking completely standard but it's not going to be easy to keep the center exit exhaust if I want to run a silencer, which I do. To be honest, I think the center exit on a Boxster looks crap anyway, i'm considering cutting the center of bumper away like has been done on this MX5. I'd then have a silencer from the back of the turbo with the pipe exiting at the driver's side of the bumperOpinions on this idea are welcome.

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Noggymike
Veteran


Car: 2002 B5 RS4
Power: 430 bhp
Torque: Whatever
Engine code: BHP

Joined: 07 Oct 2012
Posts: 12209

Location: In front of you, lol'ing

PostPosted: Tue Feb 23, 2016 10:23 pm Reply with quoteBack to top

That sounds doable, would you just leave the cut out exposed or use a diff kind of material fill the void taking into account the new exhaust position?

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ScottR
Veteran


Car: B5 S4

Joined: 22 Apr 2008
Posts: 8539


PostPosted: Tue Feb 23, 2016 10:47 pm Reply with quoteBack to top

They are far too loud with no exhaust, the turbo does little to silence. And what would be the point of making it look standard if it sounds like a monster truck!

Loving the work so far.
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Wed Feb 24, 2016 12:52 am Reply with quoteBack to top

Thanks. Someone suggested a good idea on another forum which I think i'll do. Leave the bumper alone, have a silencer hidden behind it with the tailpipe turned down and just have fake twin pipes coming out of the center in the standard Boxster location to keep the original looks. Seems obvious now I think about it.
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Kent
Skilled



Joined: 22 Sep 2012
Posts: 1735


PostPosted: Wed Feb 24, 2016 9:39 am Reply with quoteBack to top

but what about flames? I couldn't have some fake tailpipes on show. They'd have to do something on such a little beast!

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Kent
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Joined: 22 Sep 2012
Posts: 1735


PostPosted: Wed Feb 24, 2016 9:48 am Reply with quoteBack to top

cut the centre recess out and move it over to where your tailpipes need to end up and use the cutout to fill the centre section.

I know it would change the appearance from factory but it doesn't need to be ott. If you keep the factory recess and tailpipes it will look oem.

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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Wed Feb 24, 2016 8:26 pm Reply with quoteBack to top

It's true that, i'll lose some of the fun of owning this type of car with the exhaust hidden and it'd probably melt/set fire to the bumper also. I hadn't thought about moving the recess that might work.

If I can find a silencer that has the inlet and outlet the same side that's 3.5"/89mm bore I wouldn't need to mess about and could keep it centre exit like standard. The options are shit once you go past 3" and I haven't seen anything yet.
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Kent
Skilled



Joined: 22 Sep 2012
Posts: 1735


PostPosted: Wed Feb 24, 2016 8:46 pm Reply with quoteBack to top

somebody should be able to make you one dude.

Speak to Niall on here. His work is top in my opinion and he's a sound guy also...

http://audisrs.com/forum96.php

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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 232


PostPosted: Mon Feb 29, 2016 12:47 am Reply with quoteBack to top

I had a quote from someone local to make me a backbox and it's too much but i've now got a plan which should work out nice.

I made some good progress this weekend. I bought a load of exhaust parts and got started on the exhaust. I modified the exhaust manifolds with 90 degree bends (forgot to take pictures) and then made the downpipes. It was a bit of a challenge to fit two 2.25" pipes down one side of the car as space is limited, it took me a while working everything out. I'm happy with how it's turned out, especially considering all the cuts were made with 4.5" angle grinder so it was murder trying to get the angles right and the cuts straight so I had tight fits. I still need to add lambda bosses and the external wastegate pipe, then i'll heatwrap it. I think this section of the exhaust will prove to be the hardest fabrication of the whole build so I feel like it's all downhill now
 

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gtphanta
Learning


Car: Imola B5 S4

Joined: 12 Jun 2014
Posts: 81


PostPosted: Wed Mar 02, 2016 5:06 am Reply with quoteBack to top

coullstar wrote:
There is a guy over on 911uk forum that's building a rallycross boxster with a 2.7t but he is keeping the TT set up.


You have a link to that?
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