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> Boxster V8 conversion !!!, Goto last few pages and see the LS1 being fit!!!
Boxster V8 conversion !!!
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Brad Roberts
post Oct 27 2007, 09:59 PM
Post #21


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Hi Allan,

How did you handle the starter? Did you use a GM starter on the block and cut the bellhousing? Any pics?



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nocones
post Oct 27 2007, 11:16 PM
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What he said!
I'd love to see photos, and hear about the details of installation.
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ajracer
post Oct 28 2007, 10:19 PM
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Gentlemen:

The starter issue was one of the main challenges but I quickly realized there were a few
ways to address my concern and find a solution. NO we didn't use a GM starter, however
we used the stock GM starter location with a custom starter mount (which set the drive
gear about two inches closer and stock GM).

The actual start is a gear reduction unit that was provided by the starter company, and not
one that he released the actual details to me. But from my understanding it is similar to the
GM reduction starter other than it has a different drive gear to engage the ring gear. Also
I believe it was a Porsche 9 tooth / pitch drive gear.

In regards to the bellhousing, it was only very slightly modified in order to make way for
the starter drive gear clearance issues, and a removal of a casing tab which interfered with
one of the engine mounting bolts.

Some photos are attached and or will follow, but the real challenges were with the custom
components and work that is not seen. Below is a littl eintro I provide elsewhere to some
others that had also inquired regarding my Boxster V8 conversion. Happy Motoring !

A BIG QUESTION for many is more than just Tranny Prices vs Conversion costs !!
you can quite easily pick-up a used Boxster tranny (5 spd.) for about $ 1,500 - $ 2,000.
BUT you need to know the following items are necessary for the conversion in addition to
the actual tranny costs:

- two minor modifications to the tranny casing, non structure mods.
- hydraulic Clutch pedal assembly conversion.
- conversion of axles/hubs/brakes to the Porsche 5 bolt.
- Porsche 5 bolt axle assemblies and special length axles.
- Custom made adapter plate
- Custom built flywheel (for your particular engine)
- Custom Pilot Bushing/Bearing Spacer
- Special Porsche Starter Ring Gear
- Custom Clutch Assembly, Kelvar Disc.
- Custom Starter & Mounting Bracket.

No of the above items are commercially available, but would need to be designed, engineered and then custom built for you. This project was a project car for me and not
a business for me, however I did make templates of all the components mentioned above (except the hydraulic clutch conversion & 5 Bolt axles) and retained all my engineering drawings in order to re-duplicate the process or to sell to others if and when the need might arise. In my personal opinion to do this conversion it would cost over $ 5,000 for all the pieces including the tranny to complete the project. This would also depend upon your abilities as to what you can do yourself and what you would have to pay others to do. So you can see it is still a costly undertaking, BUT one sweet tranny, shifter and well working unit !


Allan
Toronto, Canada
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Brad Roberts
post Oct 29 2007, 02:16 PM
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Allan,

You did a great job!

I would like to talk to you about the adapter/clutch setup (IMG:http://www.914club.com/bbs2/style_emoticons/default/smile.gif)


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ajracer
post Oct 29 2007, 09:03 PM
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Brad:

I would welcome your inquiry and discussion; I think we can all learn from others
and usually find a workable solution to the challenges. Please drop me an email and
or PM with contact info and we can talk.

Allan Mayhew
Toronto, On CDN
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Brad Roberts
post Oct 29 2007, 09:26 PM
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Thanks Allan.



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Brad Roberts
post Jan 9 2008, 06:18 PM
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Not sure how this came back up.. (IMG:http://www.914club.com/bbs2/style_emoticons/default/lol.gif) somebody must have voted in the poll (IMG:http://www.914club.com/bbs2/style_emoticons/default/confused24.gif)



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BKLA
post Jan 9 2008, 06:25 PM
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What about a Fortin Transaxle? Will they support that HP?
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Brad Roberts
post Jan 9 2008, 06:39 PM
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No problem, but they are nearly double what he has into this (IMG:http://www.914club.com/bbs2/style_emoticons/default/smile.gif)


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Brett W
post May 25 2008, 09:53 PM
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The Boxster Gear box was rated by Getrag at 380nm of torque. Thats is about 280 ft lbs. Not much better than the 901, but at least you could use first gear without breaking it off. Here are the specs.

http://www.getrag.de/en/241
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914 Engine Surge...
post May 26 2008, 01:06 PM
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we have teamed up with the guys at Beck to put Boxster engines/ trannys into 550 replicas. The first one is underway now. I am building one into a test bed for our engine development because making changes to it will be a breeze...

I ok buy your old engine cores if you swap to a V8.
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andys
post May 27 2008, 12:21 PM
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ajracer,

If you are adapting a GEN I SBC to the 5 speed Boxster (nee Audi model 012), there may perhaps be an easier way to go about if my information is sound (?). According to the guys on the GT40 forum, the SBC to Audi (model 016 5 speed) Kennedy Eng. adapter plate will also work on the Boxster/Audi trans (5 speed). So too will their flywheel, clutch, and starter. If this is in fact the case, then it would save a great deal of work. I do know that the Boxster/Audi trans input shaft is recessed past the bellhousing surface, where as the model 016 Audi trans input shaft proturdes slightly ahead. This would of course require some changes to make up the difference.

On my GEN III (LS1) to Audi 6 speed I had to make up quite a few of custom parts to get it to work. The GEN III motor has some major differences over the GEN I SBC.

With regard to the Boxster conversion, it would seem to me that utilizing the modern Chevy GEN III (or even GEN IV) light weight aluminum V8 which has a really good EFI would be a better choice than the old school GEN I motor. IMHO.

Andys
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Andyrew
post Jun 2 2008, 04:43 PM
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Why not the 4.2 Audi v8?
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andys
post Jun 2 2008, 05:58 PM
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Andyrew,

The Audi V8 is big by comparison, overhead cams and towers, cam drive, etc. The GEN III Chevy OHV is pretty compact and makes very good power out of the box. Electronics (as you know) is another issue to deal with. I don't know anything about the Audi (stand alone, intergrated, etc), but with the GEN III Chevy there are several vendors that modify/make custom/re-program harnesses and PCM's, so no surprises there. The Audi would of course bolt right up (but you'll need Euro parts, as A8 V8's were never imported into the US with manual transmissions.

Andys
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Brad Roberts
post Sep 5 2008, 01:49 AM
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Lost but not forgotten!

Should have some Audi engineering questions answered tomorrow (IMG:http://www.914club.com/bbs2/style_emoticons/default/smile.gif)

I asked if the Audi V8 had the same bellhousing bolt pattern as the V6 S4 twin turbo (IMG:http://www.914club.com/bbs2/style_emoticons/default/smile.gif)



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Andyrew
post Sep 5 2008, 02:01 AM
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I believe so, They have the same trani I believe, but I've never pulled them so.. We'll see! If they did that means that its the same housing as the 1.8t and the 2.8 engine.
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Brad Roberts
post Sep 5 2008, 03:04 AM
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I know the 1.8T has the same bellhousing (IMG:http://www.914club.com/bbs2/style_emoticons/default/clap56.gif)

Andrew,

do you think you can locate me a Jetta or Gulf TDI engine+ tranny? Or the Audi TDI?



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davidginsberg
post Sep 5 2008, 03:07 AM
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I looked into getting the 4.2 engine to use with my 1.8t/boxster trans swap. It is the same bolt pattern. And the s4 4.2 is a REALLY small v8. They shortened the whole engine allot by placing the timing belts on the rear of the engine.
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Brad Roberts
post Sep 5 2008, 03:34 AM
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QUOTE
It is the same bolt pattern



SCORE!!!


Getting the itch to convert something.. with something cool (IMG:http://www.914club.com/bbs2/style_emoticons/default/smile.gif)



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Andyrew
post Sep 5 2008, 10:31 AM
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"Luke, use the torque"
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QUOTE
I know the 1.8T has the same bellhousing (IMG:http://www.914club.com/bbs2/style_emoticons/default/clap56.gif)

Andrew,

do you think you can locate me a Jetta or Gulf TDI engine+ tranny? Or the Audi TDI?



B


Ohh thats a hard one. I dont see them at all on the forums I am regular to.. Lemme check some others.
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