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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: 199


PostPosted: Mon Oct 31, 2016 9:53 pm  Reply with quoteBack to top

cochyn wrote:
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?


No brass balls over here, it seemed a no brainer to me and I'm surprised one of the big German tuners hasn't done it years ago. Boxster's have been cheap for years and the 2.7t is a good engine.


I'd like to see that if anyone has info on it 5 cylinder 911. Can't see that being an easy build!

Little update. It's nearly ready for a test drive but i've got a couple of issues stopping the show, it's got a leak on the charge cooler system, i'm looking into using different radiators. I'm also having problems with the oil return on the turbo, it's leaking oil past the seals into the exhaust, ordered a few bits that will hopefully put it right.

I installed a catch can so that's the engine bay finished off. This is what I started with. That's the gear selector cables that run over the inlet manifold. Seems a bit of a lazy effort from Porsche. I've got them running under the inlet manifold on the V6.





This is how much space I have in front of the engine. I'm sure anyone with a 2.7t engine in an Audi will be jealous. I fancy my chances doing a cambelt change in-situ if required. Normally when doing an engine swap I find you end up with lots of straightforward maintenance jobs that become a nightmare. I don't think there is a single job that's going to be more difficult on this car than would be on a standard Boxster or Audi S4. You can see just by looking at the flat 6 how difficult access for various jobs, the V6 is a much easier engine to work on (provided it's not in an Audi!)




I added a heat shield to protect the CV boot from the exhaust.
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bboy82
Experienced


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

Joined: 14 Mar 2011
Posts: 3298

Location: East Northants

PostPosted: Mon Oct 31, 2016 10:02 pm Reply with quoteBack to top

Haha! The original motor looks like a bag of shite by comparison!

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With courage, nothing is impossible.
Sir William Hillary
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Noggymike
Veteran


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

Joined: 07 Oct 2012
Posts: 12190

Location: In front of you, lol'ing

PostPosted: Mon Oct 31, 2016 10:59 pm Reply with quoteBack to top

Just love this project!


Glad to see it will have some additional benefits come routine service times!

_________________
PM me if you have a S4 FS, always looking for projects.
2002 B5 RS4 Noggy
2008 BMW 118d Daily slaaaag
2000 TT 225 Roadster little pocket rocket
1982 UR Quattro gem in the making
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 199


PostPosted: Tue Nov 01, 2016 10:27 pm Reply with quoteBack to top

Yeah, the original engine looks isn't exactly a masterpiece in terms of aesthetics or engineering.
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 199


PostPosted: Sat Nov 26, 2016 10:34 pm Reply with quoteBack to top

I've been slacking on this build, not touched it for a few weeks, all the rain has washed my motivation away. The MOT I thought I was being clever getting just before the start of the build has run out now. It'll be interesting to see what they make of it when the get it in the air

Finally a dry day today so I made a start. I decided I wasn't happy with the charge cooler pre-radiators so i've swapped them. Finding a suitable sized radiator has been a problem. I was talking to Rob from 9apart, a Porsche parts supplier and he said he'd have a look on the shelves. He took loads of photos of various radiators placed over the standard Boxster radiators which was a massive help. An auxiliary radiator from a Cayenne hybrid was what I went with. They only had one radiator which I got for a great price. I got my pants pulled down buying the other one, there are not many hybrid Cayennes being broken, one prat wanted more than they cost new from Porsche.



Fitted them, they are a really tight fit, not much space top or bottom for the hoses and the ducting required a lot of trimming. There is much more surface area and capacity with these radiators, going to be worth the effort I think.



Rob very kindly included some 997 GT3 brake ducts with the radiator. The Boxster with an Audi 2.7t club is very small, consisting of me and Rob This is his car. http://www.engineswapdepot.com/?p=11070 Our builds share nothing in common apart from the engine choice but he's been really helpful during my build.  
 

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Noggymike
Veteran


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

Joined: 07 Oct 2012
Posts: 12190

Location: In front of you, lol'ing

PostPosted: Sun Nov 27, 2016 6:39 pm Reply with quoteBack to top

Got to expect the sourcing of parts to be a mare and to be held to ransom on a project like this, but fair play to sticking to the game pain, sorry plan!  

_________________
PM me if you have a S4 FS, always looking for projects.
2002 B5 RS4 Noggy
2008 BMW 118d Daily slaaaag
2000 TT 225 Roadster little pocket rocket
1982 UR Quattro gem in the making
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 199


PostPosted: Sun Nov 27, 2016 6:58 pm Reply with quoteBack to top

I've been pretty lucky really with most of the part sourcing, i've picked up a few bargains along the way. Only been held to ransom on a couple of things i've needed at short notice. The one thing I wanted but couldn't stomach the cost was an RS4 inlet manifold, no chance i'm spending a grand on one which looked like the going rate.

A few upskirt shots, showing where the magic happens. I noticed i've been taking photos of little bits and pieces but not really got any showing the whole lot together. When I take it in for an MOT i'll try and get some better pictures.



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coullstar
Experienced



Joined: 20 Jan 2012
Posts: 3205

Location: Aberdeen

PostPosted: Sun Nov 27, 2016 8:38 pm 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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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 199


PostPosted: Mon Dec 26, 2016 11:22 pm Reply with quoteBack to top

Finished off the charge cooler install. I needed the rads off like this to properly bleed them, having clear pipes made the bleeding process much easier.



Finished it all up, quite a tight fit getting the rads and pipework in behind the bumper.



I had the bumper repainted as it was full of stone chips.

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Alps
Expert


Car: RS4 b5
Power: corrupts
Torque: is cheap

Joined: 06 May 2008
Posts: 4363

Location: London

PostPosted: Tue Dec 27, 2016 12:29 pm Reply with quoteBack to top

I really do not know what to say about this project other than WOW! Truly impressive.
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pk2904-rs4
Learning


Car: b5 rs4
Power: enough
Torque: for now

Joined: 23 Sep 2014
Posts: 74

Location: west midlands

PostPosted: Tue Dec 27, 2016 5:30 pm Reply with quoteBack to top

I second that...truly epic mate
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Alex Rhys
Learning


Car: B5 S4 Avant
Power: Stock
Torque: Stock

Joined: 18 Apr 2015
Posts: 98

Location: Cardiff

PostPosted: Tue Dec 27, 2016 6:00 pm Reply with quoteBack to top

Just... WoW!!! :O :O :O
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Escy
Knows a Bit


Car: Porsche Boxster

Joined: 12 Sep 2015
Posts: 199


PostPosted: Tue Dec 27, 2016 9:34 pm Reply with quoteBack to top

Thanks guys
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csdilligaf
Brand New, Welcome :)



Joined: 30 May 2016
Posts: 3

Location: San Diego CA

PostPosted: Wed Jan 18, 2017 3:19 pm Reply with quoteBack to top

Your doing a great job. I noticed you ran the shifter cables under the intake? On my project I was trying to figure out how I was going to get them around the turbo's that are right in the way. I could not respond to your PM. Said I did not have enough post's?
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jockthedog
Experienced


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

Joined: 14 Mar 2011
Posts: 3028

Location: Moonbase Alpha

PostPosted: Wed Jan 18, 2017 3:58 pm Reply with quoteBack to top

csdilligaf wrote:
Your doing a great job. I noticed you ran the shifter cables under the intake? On my project I was trying to figure out how I was going to get them around the turbo's that are right in the way. I could not respond to your PM. Said I did not have enough post's?


Post some pics of your car in the welcome forum, for example, and you'll be able to send PMs.

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Long list of shit that cost me a fortune.
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