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Old 09-28-2012, 01:44 PM   #1
kcpaz
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1998 Legacy GT
Mexico Blue (not red)

Default Subaru powered Boxster "Street Version"

This is the next conversion car that I'm working on... actually it's a pair of cars. The goal is to keep them as a street cars that can be daily driven comfortably, but still perform on the track for Time Trials. The engine on the white car is the same EJ255 that is in my green car, but the turbo will be a smaller GT2871 using factory exhaust manifolds.

The silver car will be a little different in some of it's components, but the goal is the same as far as the car's intended purpose.



GT3 front bumper

New timing belt system, water pump, welded/ported TGV's, ID1000 injectors, and secondary air injection delete.

Modified OEM Subaru wiring harness ready to be installed

Engine mocked up in chassis


Air/water intercooler in rear trunk. No goofy roof scoop needed...

Turbo and stuff...
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Old 09-28-2012, 01:58 PM   #2
kcpaz
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Here is the silver car. It's a bit of a mix of spare parts that I have been collecting.

The hard top was from another project that got a fiberglass top.


Stripped the red paint off. The plan is to run the top with a brushed aluminum finish


The silver car had a horrible "pink" colored interior...


So we ripped that out...


And installed a black interior from a 2004 Boxster S. Now it has a glove-box

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Old 09-28-2012, 02:34 PM   #3
25rsti
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Interesting....
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Old 09-28-2012, 02:52 PM   #4
Hondaslayer
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1998 Forester, lifted.

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Oh my, subscribed!
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Old 09-28-2012, 06:36 PM   #5
RonW
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sweet kent, love the projects!
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Old 09-28-2012, 08:29 PM   #6
Devilteg
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Great looking project no one will ever suspect a fast boxster haha just playing let us know how she goes when your done.
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Old 09-29-2012, 12:02 PM   #7
geronimo81
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Glad to see everything has proven itself in the green car. I hope some of the people that have been bugging you for a street setup will actually follow through with orders.
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Old 09-29-2012, 02:12 PM   #8
kcpaz
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Quote:
Originally Posted by geronimo81 View Post
Glad to see everything has proven itself in the green car. I hope some of the people that have been bugging you for a street setup will actually follow through with orders.
Me too.
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Old 09-30-2012, 12:29 AM   #9
RSti_Spyder
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As always nice to see your projects...
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Old 09-30-2012, 05:44 PM   #10
PHATsuby
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to stock is a project too

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This will be fun to follow as well.

I am curious what size tubing and wall thickness do you use for the tubular subframes to mount the engine? And do you just use a manual tubing bender to make the bends? I may have to do some of that in the future so I'm curious how the pros do it and what materials.

Thanks, good work.

Ben
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Old 10-03-2012, 12:13 PM   #11
ScottyB
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very, very excited to see where this goes. as boxster prices come down, i keep letting myself get intrigued to buy one but i just can't consider it until there's a reliable and complete solution to getting rid of the stock powerplant. i'll be following this progress closely. nice job!
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Old 11-15-2012, 02:48 AM   #12
cpturbo
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Any updates, Sir??
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Old 11-16-2012, 11:47 AM   #13
kcpaz
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Sorry, been busy with other projects. I have managed to do some work on the cars though.

The white car will be done first, and should be running by the end of the year.

The silver car is being built at the same time, but will have a custom roll car, and some other modifications that will happen before the engine goes in.

I went back and forth on the OEM exhaust manifolds, and decided that it's just not worth the compromises in ground clearance and pre-turbo exhaust length to use the OEM manifolds. Instead, I decided to make a tubular header system that mimics the OEM exhaust in design, but increases flow capabilities, and moves the location of the "up-pipe" to the driver's side for a more direct path to the turbo.

I've also decided that the use of an OEM style turbo is not something that we will plan on. The orientation of the turbine/compressor housings on the stock frame turbos, along with the function of the internal wastegate, and location of the fluid line fittings, make things too complicated. This will also simplify our exhaust options to the use of either T25, T3 and T3 twin scroll... and possibly T4 if someone really wants to run a large turbo.
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Old 11-18-2012, 04:12 AM   #14
kcpaz
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Some pictures of the exhaust and intercooler system...









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Old 11-18-2012, 07:04 PM   #15
cpturbo
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I like it! So, I am glad that T4 is an option. Is this location amenable to gravity oil drainage? Looks good. Are these parts ready to ship if I order up a kit? I also need an electric power steering kit recommendation.

Thanks
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Old 11-18-2012, 10:52 PM   #16
kcpaz
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Quote:
Originally Posted by cpturbo View Post
I like it! So, I am glad that T4 is an option. Is this location amenable to gravity oil drainage? Looks good. Are these parts ready to ship if I order up a kit? I also need an electric power steering kit recommendation.

Thanks
I'm not 100% sure, but I really doubt that gravity return would work based on the turbo location. The factory return port in the head is definitely too high, so you would have to weld a bung into the oil pan, but that's not something I am planning on doing on any of my cars. A scavange pump is the way to go IMO.

I could help you with some information on the electronic power steering pump if you decide to go that direction, but unless you are building a dedicated race car, I would just use the Subaru mechanical pump. It simplifies things a lot.

Send me an email for more details on the availability question.
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Old 11-19-2012, 11:47 AM   #17
DeleriousZ
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Damn man your welding skills are impeccable! This is such a cool project!
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Old 11-19-2012, 03:50 PM   #18
ecbmxer
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This is awesome! If you start producing these conversion kits I bet a bunch of people will be running around in Subie powered Porsches! Aren't Boxers with blown engines pretty easy to find?
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Old 11-19-2012, 06:20 PM   #19
Extreme Turbo Systems
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Looks really good. Actually perfect for a water/air setup. you can run the heat exchanger up front which increases the capacity for water and will make it really hard to heat soak.
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Old 11-21-2012, 12:21 PM   #20
wtyree
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Subscribed.
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Old 01-18-2013, 06:41 PM   #21
johnvan8
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subscribed
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Old 01-21-2013, 09:50 AM   #22
Stangy
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pumped
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Old 01-21-2013, 10:05 AM   #23
bchasc
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Very impressive...subscribed
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Old 05-13-2013, 07:50 PM   #24
cpturbo
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How much horsepower can that intercooler handle? Are those cars up and running?
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Old 05-15-2013, 12:23 PM   #25
kcpaz
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Garrett rates the intercooler at 750hp.

These cars had to take a back seat to some other projects in the shop (BMW related) but the white car was 80% complete when we stopped. They should resume progress in the next month.
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