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Old 08-31-2010, 04:03 AM   #1
kcpaz
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Default EJ255 into a Porsche Boxster

So this is the first step. Engine is bolted to the 6 speed transaxle via custom adapter plate. Next is fabricating motor mounts and other operating systems.





The donor car is a 2000 Boxster S that I purchased with a blown motor. The plan is to build this car to compete in NASA's TTS and ST2 classes, with the primary goal of testing the conversions for reliability prior to offering them to the general public.

The goal is for the car to weigh no more than 2300lbs wet without driver, and have a power-to-weight ratio of no less than 8.7:1 in order to fit into the designated classes.
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Old 08-31-2010, 04:05 AM   #2
kcpaz
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The body will have flared quarter panels and fenders to accomidate 315mm tires out back, and 275mm tires in front...

Rear fender flares are also bonded on...




New body work in front too...


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Old 08-31-2010, 04:07 AM   #3
kcpaz
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Test fit the engine today to see how it fits. It's almost like it was meant to be. It almost looks like the turbo might be able to fit in the stock location on the engine, although that's not what I will be doing on this car. There is almost 6 inches between the crank pulley and the engine bulkhead which is WAY more than the stock M96 engine.
Next is motor mount fabrication.





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Old 08-31-2010, 04:08 AM   #4
kcpaz
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Prototype motor mount/cradle is finished. It mounts using factory hardware locations, and requires no chassis modification or welding. The bottom of the cradle also acts as a skid plate of sorts since the oil pan sits about a half inch lower than the stock oil pan.



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Old 08-31-2010, 04:10 AM   #5
kcpaz
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Turbo and supporting pieces. The turbo is a twin scroll GT3076R
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Old 08-31-2010, 04:29 AM   #6
Flyin_Hayn
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this looks amazing.. great work with the motor mount.. cant wait for final product! ill be keeping up on this

*subcriibed!
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Old 08-31-2010, 08:54 AM   #7
CatfaceType-R
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bad ass build man, subscribed
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Old 08-31-2010, 09:46 AM   #8
Jaxx
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wow
what is your plans for EM?
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Old 08-31-2010, 10:10 AM   #9
kcpaz
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Quote:
Originally Posted by Jaxx View Post
wow
what is your plans for EM?
stock Subaru... Which is the reason for the other thread of mine that you just replied to...
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Old 08-31-2010, 10:54 AM   #10
FyrHazard
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Subscribing! Always wondered if anyone did this...
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Old 08-31-2010, 12:42 PM   #11
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Old 08-31-2010, 01:26 PM   #12
glvr
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finally a boxster with a boxer engine :P lol
thats too legit man. cant wait to see the finished product
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Old 08-31-2010, 01:29 PM   #13
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*sprut*. Why the choice of a Subaru mill? Cost/aftermarket?
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Old 08-31-2010, 01:32 PM   #14
WHAT
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going to be AWD or just RWD? Sorry if this was answered in another thread?
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Old 08-31-2010, 01:43 PM   #15
REX8
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Quote:
Originally Posted by WHAT View Post
going to be AWD or just RWD? Sorry if this was answered in another thread?
He's using the porsche trans, so rwd.

Why would you destroy the balance of the car with awd I don't know...
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Old 08-31-2010, 02:32 PM   #16
Matt Monson
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When are those adapter plates coming to market? I need one for my 914...
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Old 08-31-2010, 04:27 PM   #17
kcpaz
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Quote:
Originally Posted by LastResort View Post
*sprut*. Why the choice of a Subaru mill? Cost/aftermarket?
The Subaru motors are FAR SUPERIOR to the M96 Porsche engines in every way. The Subaru engines are lighter, make more power, are cheaper to maintain, cheaper to buy, more reliable, and more compact.
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Old 08-31-2010, 04:27 PM   #18
kcpaz
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Quote:
Originally Posted by Matt Monson View Post
When are those adapter plates coming to market? I need one for my 914...
Probably by the end of the year
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Old 08-31-2010, 04:37 PM   #19
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Dang! Looking great! If you're weighing in at 2300 lbs, your power to weight ratio is going to be closer to 6.5 lbs/hp with that turbo. Very nice!
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Old 08-31-2010, 05:50 PM   #20
kcpaz
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Quote:
Originally Posted by JRach View Post
Dang! Looking great! If you're weighing in at 2300 lbs, your power to weight ratio is going to be closer to 6.5 lbs/hp with that turbo. Very nice!
You also have to add the weight of the driver (about 200lbs)... but yes, the turbo will be capable of more than I will be using at first unless I decide to go up to the next class.
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Old 08-31-2010, 06:13 PM   #21
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Awesome project, and the best part is it'll piss off Porsche snobs.

So what all do you plan to include in the kit?
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Old 08-31-2010, 06:38 PM   #22
kcpaz
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Quote:
Originally Posted by Eby View Post
Awesome project, and the best part is it'll piss off Porsche snobs.

So what all do you plan to include in the kit?
Depends on the car and it's intended purpose. There will be a "race kit" which is what the test car will have, and a "street kit" which will have slightly different exhaust and intercooler design, along with the ability to run A/C. Basically, there will be a lot of different options that people will be able to choose from, and each complete kit will be made to order. People will also be able to buy pieces if they want to try and to some of the aspects of the conversion on their own.

I don't want to say too much because I don't want people to think I'm trying to advertise with this thread (as I'm not a paid supporter). That's not my intention right now. For now, I just want this to be informative.
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Old 08-31-2010, 11:24 PM   #23
olsen726
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this project is sweet.. i should have started coming into the "subaru Conversions" area a long time ago
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Old 09-01-2010, 12:41 AM   #24
Kostamojen
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This thread is very much relevant to my interests.

That adapter plate for the boxter 6-speed... isn't that the transmission some folks have been trying to use in their Subaru/914 swaps?
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Old 09-01-2010, 12:49 AM   #25
PHATsuby
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to stock is a project too

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This is a sweet project! Nice work on the engine frame/mounts and everything. Makes me want a porsche with no motor so I can do a swap too.

Ben
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