Project 914-LT1 Canadian V8 conversion, Getting Started with Engine Build-up Options

[ajracer]

Last one for tonight

[Aaron Cox]

can you elaborate on your wilwood calipers?

[ajracer]

Aaron; what would you like to know.

The Wilwood's are installed on the front. I used the 911 Boge struts with
Koni inserts. The wilwood's mounting holes were also 3.5" apart, however
I needed to fabricate some spacer to correctly align the calipers with the
centre of the rotors. I believe they were about 5mm thick alumimum ones
which I cut out and then drilled on a cheap drill press. Since I acquired a
sdecent set of 944 front hubs and rotors I used these vented rotors with
the Wilwood calipers. (These are four pods, medium agressice pads, racing
with no dust shields; but mainly a weekend street machine with some AX
and possible solo 1 / 2 events).

Not sure if you want more info, but let me know specifics of what you want
to know I will try to assist. Good Luck

Allan

Photos below

[ajracer]

another photo

[bondo]

Ok, now can you elaborate on your transmission? (IMG:http://www.914world.com/bbs2/html/emoticons/smile.gif) How are you going to shift it? What RPM will your highway cruise be? How hard was it to make it fit? (I figure my 901 won't last forever, and it looks like you're trail blazing)

[redshift]

Uh... yes... tell us all about that.

(IMG:http://www.914world.com/bbs2/html/emoticons/smile.gif)


M

[GWN7]

Audi trans (he said so earlier) (IMG:http://www.914world.com/bbs2/html/emoticons/wink.gif) but I'd like to hear the details too

(IMG:http://www.914world.com/bbs2/html/emoticons/biggrin.gif)

[rick 918-S]

Very cool! (IMG:http://www.914world.com/bbs2/html/emoticons/smilie_pokal.gif) Show us more on the Audi box! (IMG:http://www.914world.com/bbs2/html/emoticons/clap.gif)

[ajracer]

Gentlemen; here we go with INFO

Yes Bondo you are correct in that I am kind of trail blazing !
Or more like trial and error (hopefully not too many errors).

Let me first say that I wanted to keep this “project” an little secret until I had everything completed, after my designing, engineering and fabrication of the various components that have gone into this project. In saying that I am a very honest person but may have been a little vague with some issue, ESPECIALLY the fact concerning my transmission plans. Bruce; I did mentioned that many tranny plans included an “Audi type” transmission (seeing that the actual Porsche tranny components in this case are mfg. By Audi and include their insignia) BUT the actual fact is I decided to use a 1998 Boxster Five speed !!!! Sorry to be a little misleading but I wanted to keep quiet about this little “Canadian Project” car until basically completed.

There were many reasons for this choice, but the main one was that after I had purchased an aluminum 915 tranny, did my own extensive research and concluded I would need to spend another large sum of $$$ to upgrade for mid engine, gear ratios and then custom order shifter, etc, etc. Then at best I still had a “915” tranny which I understand even a Porsche 6 cyl. can destroy !

SO here I am with a V8 Chev 350 LT1 balanced , blue printed and a good BOXSTER transmission !!! Hopefully I will have the vehicle on the road within a month or two once I complete the installation of the various items necessary to roadworthiness.

I have not, nor do I actually plan to open the tranny or make any internal changes ! But I have fabricated my own set-up to retain the cable clutch operating unit back until the tranny. THEN I have added a lever linkage set up to activate the clutch arm within the Boxster tranny. The details of the actual flywheel, starter, pressure plate, clutch disc will likely remain a private issue at this time. As well the actual engine tranny adapter plate is also a custom item I designed and fabricated which has some unique features. In all this has been a challenging project of looking for potential problems and then developing solution before the problems materialized. Yes there will likely be additional problems, challenges and hopefully more solutions; thus the challenge of trail blazing !! I guess I am a bit of a risk taker, willing to try something new or different with the hope of getting a different of better result when completed. Time will tell !!!

Gear ratios should be acceptable for V8, the shifter is “Stock" Boxster transplanted with an adapter plate into the original 914 shifter mount. The Boxster CABLE SHIFTER is a great work of art and one that I am really pleased with !! As you can notice from the last couple of photos this is really only a trial fitting and I need to locate the sweet spot for the engine and then fabricate a tranny mount and start getting ready to roll down the side streets of Toronto.

I will also try a attached a couple of additional photos that may indicate some of the progress along the way regarding this tranny set-up. Once completed and operational I would be more than pleased to provide additional feedback and possible supply custom components should some others be interested in using either the Boxster Five speed or even Six speed tranny. (Yes they are different but the solutions necessary to use with a V8 are similar). Thanks again for following along and happy motoring teeners !!

Allan

[bondo]

(IMG:http://www.914world.com/bbs2/html/emoticons/smilie_pokal.gif)

Awesome! Can't wait to see the finished product!

[ajracer]

Photo# 1

[ajracer]

Photo# 2

[ajracer]

Photo# 3 prior to first trial fitting in vehicle

[bondo]

Man, that's so awesome. How much does a boxster trans cost? How much torque can it handle?

[ajracer]

Royce;

Thanks for the compliment, and hopefully we can share more on our LT1 coversions.

But like I said before I am running pieces of the Rod Simpson kit along with some

customs fabricated components I wanted or needed to use because the late model

LT1 engines are reverse cooling. In addition I modified the RSH water pump to get

a better flow.


I also did away with the "opti spark" unit and placed a conventional distributor

in the rear and basically engineered the LT1 "backwards" to get a later model LT1

that "looks" like an early V8 !!!. Good luck with your project !


Allan


PS. There was an error with the drivers side bottom outlet; it was later modified to
exit 90 deg. to right of the position in the attached photo. (just in case you or
someone else decided to fab from my illustration).

[ajracer]

Royce;

another photo of the timing cover around the time it was being modified

with some grinding, plugs, etc. to adapt for the earlier style engine.

[neo914-6]

QUOTE (ajracer @ May 25 2005, 07:19 PM)

Gentlemen; here we go with INFO Yes Bondo you are correct in that I am kind of trail blazing ! Or more like trial and error (hopefully not too many errors). Let me first say that I wanted to keep this “project” an little secret until I had everything completed, after my designing, engineering and fabrication of the various components that have gone into this project. In saying that I am a very honest person but may have been a little vague with some issue, ESPECIALLY the fact concerning my transmission plans. Bruce; I did mentioned that many tranny plans included an “Audi type” transmission (seeing that the actual Porsche tranny components in this case are mfg. By Audi and include their insignia) BUT the actual fact is I decided to use a 1998 Boxster Five speed !!!! Sorry to be a little misleading but I wanted to keep quiet about this little “Canadian Project” car until basically completed. There were many reasons for this choice, but the main one was that after I had purchased an aluminum 915 tranny, did my own extensive research and concluded I would need to spend another large sum of $$$ to upgrade for mid engine, gear ratios and then custom order shifter, etc, etc. Then at best I still had a “915” tranny which I understand even a Porsche 6 cyl. can destroy ! SO here I am with a V8 Chev 350 LT1 balanced , blue printed and a good BOXSTER transmission !!! Hopefully I will have the vehicle on the road within a month or two once I complete the installation of the various items necessary to roadworthiness. I have not, nor do I actually plan to open the tranny or make any internal changes ! But I have fabricated my own set-up to retain the cable clutch operating unit back until the tranny. THEN I have added a lever linkage set up to activate the clutch arm within the Boxster tranny. The details of the actual flywheel, starter, pressure plate, clutch disc will likely remain a private issue at this time. As well the actual engine tranny adapter plate is also a custom item I designed and fabricated which has some unique features. In all this has been a challenging project of looking for potential problems and then developing solution before the problems materialized. Yes there will likely be additional problems, challenges and hopefully more solutions; thus the challenge of trail blazing !! I guess I am a bit of a risk taker, willing to try something new or different with the hope of getting a different of better result when completed. Time will tell !!! Gear ratios should be acceptable for V8, the shifter is “Stock" Boxster transplanted with an adapter plate into the original 914 shifter mount. The Boxster CABLE SHIFTER is a great work of art and one that I am really pleased with !! As you can notice from the last couple of photos this is really only a trial fitting and I need to locate the sweet spot for the engine and then fabricate a tranny mount and start getting ready to roll down the side streets of Toronto. I will also try a attached a couple of additional photos that may indicate some of the progress along the way regarding this tranny set-up. Once completed and operational I would be more than pleased to provide additional feedback and possible supply custom components should some others be interested in using either the Boxster Five speed or even Six speed tranny. (Yes they are different but the solutions necessary to use with a V8 are similar). Thanks again for following along and happy motoring teeners !! Allan

Good choice Allan! I have the Boxster 5 as well for my Audi V6tt conversion. I bought it for a very reasonable $1000 which included a nice B&M short shifter and cables. The shifter came after finding my rear exhaust bosses cracked. The tranny has a very simple shifter set up similar to 914 Audi 1.8t's cable shifter (although he designed his rear pivot levers since it was not designed for mid-engine) My clutch should be a bolt-on if not close coming from the same manufacture "family". My Boxster tranny even has Audi markings. The "S" 6-speed is quite different where the starter pocket is located and has less shift linkage. I would like to use the 6-speed but I've found they sell for 3x the cost of a 5 speed.

[ajracer]

UPDATE

Engines IN - ready to fire later this week

Tranny IN - cable shifter installed and fabricated special cable brackets

Brakes DONE - and bleed appear to be fine (four piston calipers all around)

Rear Fiberglass Flares - temporarily installed (need to be bonded and fiberglassed

Wheels & spacers - installed and clear body. (255/50/17's on rear)

Radiator - almost done mounting unit and completing the aluminum enclosure.


IF things go well this week it should be running and ready to drive after installing
some mufflers !! Wish me luck and hopefully things will come together. Planning to
take as my "project car" to the "Canadian Por' Volks Festival" may even trailer for
display if not driveable.

Allan

PS some photos attached

[ajracer]

Rear stance

[ajracer]

Tranny set-up - rear view