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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: 173


PostPosted: Sun Sep 04, 2016 11:32 pm  Reply with quoteBack to top

I went to see my friend who's got an Audi S4 and took my ECU, throttle body and pedal with me so I could try them on his car to work out what's causing my DBW problems. Turns out it's the ECU which is what I thought initially.



At least now I know I can go DBW on a standalone and not expect problems.
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 173


PostPosted: Fri Sep 09, 2016 7:41 pm Reply with quoteBack to top

Before condemning my Audi ECU to the scrap pile I flashed the standard map back on it. My friend had changed the injector and MAF housing sizes in the parameters so we could get it started but it turns out this had caused problems with some other code in the ECU as once the standard map file was back on, all the error codes I had previously been pulling my hair out over are now gone. The drive-by-wire throttle is working perfectly. It' a relief to see it working.

I could keep the Audi ECU since it's all wired up but the decision has been made to go standalone. I've gone for an EcuMaster EMU, it's got plenty of features and it is very good value for money compared to other similar ECU's. I've bought the additional drive-by-wire unit and a Bluetooth adaptor which can display all the data on my phone/tablet, this will definitely come in handy as it means I can start mapping without needing to worry about getting the Boxster gauges working straight away.



The wiring loom was too long before and it was all coiled up in the boot as it seemed like too much hassle to shorted it when using the Audi ECU but now I have an excuse to take a huge section out of it when wiring the new ECU in. It sounds easier than it is as there are loads of splice points inside the loom which I'll need to re-do. It shouldn't take me long to wire up as I've spent so long looking at wiring schematics in the last month they are practically burnt into my vision like arc-eye.
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 173


PostPosted: Wed Sep 21, 2016 7:49 pm Reply with quoteBack to top

I've got the new ECU wired up. I was lucky enough to pick up an RS4 basemap from a guy called Michele who works for Dutter Racing in Austria. First thing was to get the DBW throttle set-up correctly, i'm using the original Porsche pedal sensor rather than an Audi one. I've not used any software like this before and it's quite a steep learning curve, I was having problems with the throttle plate working the wrong direction (closed with the pedal depressed).  Michele who sorted out the map helped me out massively, he logged onto my laptop remotely and set it all up for me, it took a while as I had the wrong firmware on the ECU causing some problems. Technology is awesome when someone in Austria can fix your car through the internet.

Here is a little video of the DBW throttle working. Not really that impressive but it feels like a triumph after all the troubles i've had in the past.

https://youtu.be/XzDL8D5ptCw

I should be able to try and start it up soon. I've noticed an oil leak in the middle of the Vee of the engine so i'm going to take the inlet manifold off to investigate before I start it up.
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Noggymike
Veteran


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

Joined: 07 Oct 2012
Posts: 11967

Location: In front of you, lol'ing

PostPosted: Wed Sep 21, 2016 8:03 pm Reply with quoteBack to top

Hats off to your patience!

_________________
2002 B5 RS4 Noggy
1998 B5 S4 Noggy Avant, (sold)
2008 BMW 118d Daily slaaaag
2000 TT 225 Roadster (on going project)
1982 UR Quattro gem in the making
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 173


PostPosted: Thu Sep 22, 2016 8:34 pm Reply with quoteBack to top

Another bit of homebrew fabrication...

I wanted to make a brace that ties the rear suspension subframes together, apparently it makes a big difference on a standard car as it keeps the geometry of the rear suspension correct during hard cornering. I've got wider rear tyres and the Quaife so want to make the most of it. There are a couple of aftermarket braces out there but they wouldn't fit as my gearbox sits lower in the chassis and my exhaust runs through the same area so I decided to make one. I had an old rear strut brace kicking about in the garage from an Ek9 I broke for parts years ago so I decided to see if I could use it.



To get the angles correct so I had the clearance I needed I had to chop it up into 5 parts, I also needed to change the brackets about. The brace is made from aluminium and I don't have the equipment to weld it so I had to come up with another way to put it back together. It's hollow inside and I happened to have a V-coil kit the right size for it so I tapped the threads, fitted the inserts and put it all back together with studs holding it all together. I then finished it off with some JB weld. I guess it's a little unorthodox but I am pleased with it considering I didn't have a clue how I was going to do it when I started cutting it up.



I got it back from the powder coaters today. It won't actually be seen when the car is done as there is an alloy breast plate that bolts under it. The clearance is tight in a few places, there was a couple of times while I was making it I thought I might be wasting my time.



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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 173


PostPosted: Mon Sep 26, 2016 12:42 am Reply with quoteBack to top

I'm using a chargecooler system on my car. For anyone that doesn't know, a charge cooler system uses water to cool the hot charge air from the turbo. It comprises of an air to water radiator mounted at the front, a water pump, a charge cooler core and a header tank, it uses it's own coolant, separate from the engine.

I've not had any experience with a chargecooler system before so I looked around at what others have done. It seemed that the majority of people that use one tend to generally be disappointed by it's performance when compared to an intercooler, there are lots of things to consider and it's difficult thing to get right as you need the pump as low as possible and the header tank at the highest point, it's easier said then done when trying to find places to fit things and it not look crap.

There isn't much space at the front of a Boxster, it's impressive how Porsche have mounted the radiators, they've made the most out of the available airflow with some nice ducting. I don't want to mess with the shrouds as it's not like i'm going to be able to design anything better. Being a Boxster S, it has the extra radiator in the middle. Most Boxsters that are turbocharged use this centre radiator as the charge cooler radiator, I spoke to someone who tried it, the verdict was "fine on the street, won't cope on track". With that in mind I decided to go a different route and fit a pair of radiators either side in front of the engine radiators. I bought a pair of Polo radiators but they were too big, I then bought a pair of classic Mini radiators but they were also too big. I looked into large oil cooler radiators, quad bike and motorbike radiators but couldn't find anything the size I wanted so I thought I may as well see if I could use the air conditioning condensers (modified to take larger pipes).






I ran the pipework where the old a/c pipes used to be, up over the front arch liner, under the floor and into the boot through the air vent. I've put 6 bleed points in the various high points of the pipework.




I initially bought a Bosch pump (the one used on the Mk1 Focus RS) but took some advice that it wasn't going to be up to the job. I started looking at other options and it looked like the Pierburg pumps are the best performers, I'm using a CWA-50 which is controlled by a tiny-CWA from Tecomotive. It will allow me to have the pump speed controlled by the coolant temperature, no point in blasting coolant around at full speed if i'm sat in traffic. I have to say, Tobias at Tecomotive was extremely helpful.



The chargecooler core was mounted in the boot, I went for a pretty large one. I bought a header tank from the US, there aren't many options I found in the UK. The tank is 5.5 litres, the more water capacity, the longer it will take to warm up. I don't know what the total capacity is, would probably say around 15 litres. I wish I could weld alloy so I could design my own bits as using off the shelf parts has made for a compromise. The tank should be the highest point of the system but I can't mount it any higher as sit's under the rear light and that's pretty much the only place it was going to fit. As the highest point is the chargecooler, i've drilled a hole and added a bleed screw that i'll use to top the system up, the cap on the tank will stay closed. You can see the Tecomotive pump controller in the picture, it's the red square that's by the expansion tank, it'll be mounted into the boot carpet.



It's taken me a while putting it all together, i'm please with how the install looks, hopefully i'm pleased with the results.
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DamianS4
Brand New, Welcome :)


Car: Audi S4 Avant 2001
Power: 350
Torque: 510

Joined: 14 Jun 2011
Posts: 28

Location: South

PostPosted: Tue Oct 25, 2016 11:53 am Reply with quoteBack to top

Update?

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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 173


PostPosted: Tue Oct 25, 2016 2:31 pm Reply with quoteBack to top

It's getting colder and darker which doesn't help my motivation. I'm still making progress. I've wired in the new ECU and had the engine running but had a couple of issues inside the fuel tank with the quick release pipes coming off as the fuel pressure built. Once I had the engine running it became apparent that I needed to redesign the oil return from the turbo as oil was leaking past the turbo seals into the exhaust and boost pipes, i've done it but not tested yet. I've also had a couple of engine oil leaks and exhaust blows I've had to sort out.

I'm not far off being able to drive it, hopefully soon
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bboy82
Experienced


Car: K04'd B5 S4 Saloon
Power: TBC
Engine code: AGB

Joined: 14 Mar 2011
Posts: 3260

Location: East Northants

PostPosted: Tue Oct 25, 2016 5:12 pm Reply with quoteBack to top

Keep up the good work fella!

There's a lot of us out here that are looking forward to the finished article.


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Noggymike
Veteran


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

Joined: 07 Oct 2012
Posts: 11967

Location: In front of you, lol'ing

PostPosted: Tue Oct 25, 2016 7:29 pm Reply with quoteBack to top

bboy82 wrote:
Keep up the good work fella!

There's a lot of us out here that are looking forward to the finished article.



+1

_________________
2002 B5 RS4 Noggy
1998 B5 S4 Noggy Avant, (sold)
2008 BMW 118d Daily slaaaag
2000 TT 225 Roadster (on going project)
1982 UR Quattro gem in the making
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Dryden51
Brand New, Welcome :)


Car: RS4 B5
Power: ~460bhp
Torque: ~673nm

Joined: 18 Feb 2011
Posts: 46


PostPosted: Wed Oct 26, 2016 10:49 am Reply with quoteBack to top

I've followed this build from the start - Amazing work! Can't wait for actual footage of this thing on the move, it'll be awesome...
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bboy82
Experienced


Car: K04'd B5 S4 Saloon
Power: TBC
Engine code: AGB

Joined: 14 Mar 2011
Posts: 3260

Location: East Northants

PostPosted: Wed Oct 26, 2016 12:26 pm Reply with quoteBack to top

I'd love to see some Go-Pro footage shot from a mount on the rollover bars...

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With courage, nothing is impossible.
Sir William Hillary
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 173


PostPosted: Sat Oct 29, 2016 8:19 pm Reply with quoteBack to top

I plan to try and get some decent videos once it's up and running. Might see if one of the YouTubers that does modified cars wants to do a video on it, will do a better job than me.

Hopefully I can get it on track and get some videos of me mashing up 911's
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cochyn
Knows a Bit



Joined: 19 Jan 2015
Posts: 123

Location: West Yorkshire

PostPosted: Sun Oct 30, 2016 1:39 am Reply with quoteBack to top

Escy: You have the brassiest of brass balls to take this on. If I were a hat-wearer, I'd doff it in your direction.

Off topic: Does anyone on here remember some Dutch(?) lad who tried to stick a 5-pot S2 ABY engine in a 993/ 964 Porka back in the day?

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Avus B5 RS4
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coullstar
Experienced



Joined: 20 Jan 2012
Posts: 3135

Location: Aberdeen

PostPosted: Sun Oct 30, 2016 8:56 am Reply with quoteBack to top

Brilliant.

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B5 RS4 - Avus
Corrado Storm
T5 2.5 Shuttle - daily dog
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