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

[ajracer]

LAST one - rear flares (temporarily installed but ready for final prep and

then bonded to the body with Urathane adhesive and followed by fiberglass.

[John2kx]

AJ,

Interesting project. I look forward to seeing the finished product and hope you continue documenting your findings. The transaxle choice is interesting.

John

[neo914-6]

Looking great Allan (IMG:http://www.914world.com/bbs2/html/emoticons/clap.gif)

I've been thinking lately about the Boxster tranny for my V8 as well. How much hp/torque are they rated? It should be stronger than the 901 and the 6 speed should be stronger yet. I believe the 5 and 6 speeds are interchangeable even with the bellhousing differences. The 5 speed price makes them "disposable" like the 901's. If you market an adapter & mount kit, I'll be a customer. (IMG:http://www.914world.com/bbs2/html/emoticons/biggrin.gif)

[andys]

QUOTE (Neo914-6 @ Aug 15 2005, 01:43 PM)

Looking great Allan (IMG:http://www.914world.com/bbs2/html/emoticons/clap.gif) I've been thinking lately about the Boxster tranny for my V8 as well. How much hp/torque are they rated? It should be stronger than the 901 and the 6 speed should be stronger yet. I believe the 5 and 6 speeds are interchangeable even with the bellhousing differences. The 5 speed price makes them "disposable" like the 901's. If you market an adapter & mount kit, I'll be a customer. (IMG:http://www.914world.com/bbs2/html/emoticons/biggrin.gif)

The 5 speed and 6 speed transaxles are completely different. The 6 speed has a starter mount @12 o'clock, and hangs out the back. The 5 speed has the starter pocket @ about 4 o'clock, and it faces forward.

The Audi 5 speed is the model 012, used on everything Audi (longitudinal) up to the big A8. Later Quattro's use the 6 speed model 01E. Ratio's vary on the 012, so you need to know the codes and extract the R&P and 1 thru 5 gears. The standard Boxster 5 speed has ratio's nearly identical to a 901, so you gain no advantage there. The following are "net" ratios (R&P x gear), 1 thru 5
Porsche 901 13.69 8.37 5.58 4.10 3.14
Porsche Boxster 5 sp 13.62 8.24 5.56 4.01 3.07

Andy

[neo914-6]

QUOTE (andys @ Aug 15 2005, 03:41 PM)

The 5 speed and 6 speed transaxles are completely different. The 6 speed has a starter mount @12 o'clock, and hangs out the back. The 5 speed has the starter pocket @ about 4 o'clock, and it faces forward. The Audi 5 speed is the model 012, used on everything Audi (longitudinal) up to the big A8. Later Quattro's use the 6 speed model 01E. Ratio's vary on the 012, so you need to know the codes and extract the R&P and 1 thru 5 gears. The standard Boxster 5 speed has ratio's nearly identical to a 901, so you gain no advantage there. The following are "net" ratios (R&P x gear), 1 thru 5 Porsche 901 13.69 8.37 5.58 4.10 3.14 Porsche Boxster 5 sp 13.62 8.24 5.56 4.01 3.07 Andy

I noticed the starter differences which is why I chose the 5 speed for the 2.7 Audi. Jason has both 5 and 6 speed and tells me his cases are identical. Apparently there are two versions of 5 speed Boxsters, one for 2.5 and one for 2.7. Maybe the later has the starter location change...

The advantages I see are the relatively low price to a rebuilt 901, modern engineering and materials, nice cable shifter. Once the mounting and speedo is adapted, you will only need to replace it when it fails.

[ajracer]

Greetings:

Well just hour before the weekend and FIRE-UP the baby and evaluate how
everything is before maybe a spin around the country at the Canadian Por
Volks Festival this Sunday.

Just re-installed the tranny this evening, my own Custom Flywheel, a new
Kevlar Clutch and Special Pressure plate. An YES for any newcomers viewing
this thread BOXSTER tranny behind my Chevy LT1 350. A few days ago finished
up the cable shifter brackets, fabricated a clutch linkage in order to maintain the
914 cable set-up. No sure about the operation of clutch set-up yet, but can
always convert to hydraulic if needed. Radiator, shroud, fans and electronics
also went in over past few days.

Just need to ADD the Water, hook up electrics for fuel pump and should be
Vroom, Vroom, Vroom. Update to follow; excitement is GROWING !!


Allan

[Mueller]

(IMG:http://www.914world.com/bbs2/html/emoticons/smilie_pokal.gif) (IMG:http://www.914world.com/bbs2/html/emoticons/pray.gif) ....man, I'm excited for you...get that puppy running (IMG:http://www.914world.com/bbs2/html/emoticons/boldblue.gif) (IMG:http://www.914world.com/bbs2/html/emoticons/clap.gif)

[ajracer]

Puppy is RUNNING !!!

Since I never really finished the vehicle to drive it to the "Canadian Por Volks Festival
" hosted by Mark's Airt Cooled; I decided to at least get it mobile and trailered to he show.

Since this is a "work in progress - project car" I thought it would be a great idea.
Even brought along some tools, supplies, etc to complete a few last minute minor
details to "Fire-up" at the show. Was not able to keep my appointment yesterday
to have the mufflers installed, but hey open header still sound GOOD to me!
So after taking deliver of the roller last summer, I decided after a year it would be
a good idea to at least wash the dirty car which spent the last twelve months in
garage(s) was on jack stand. Only yesterday did I get to install the 944 turbo axles,
added water this mornring. Like any conversion project there are problems or the
unexpected and the teener was no exception. After connecting the electric fuel
pump wires found no power and had to build a last minute harness and a few minor
items before fire up. She picked up the fuel so quickly I think I might have even
flooded the engine. But no start; so backwards we go checking items and found a
couple problems which were corrected.

Turn the key and she sputters a few times, relocate all the plug wires one position
on the distributor cap and try again THIS time she takes right off and within
seconds (with open headers) a few bystanders decided to check out this loud noise
and wonder what kind of vehicle it this ??

Attached photo of the nice (but not so pretty teener) on her way after boarding
the trailer. More info to follow soon, still need to add mufflers and adjust up the
clutch linkage. Driving it seems like a reality this week !!!!!!


Allan

[neo914-6]

"This thread is useless without audio" (IMG:http://www.914world.com/bbs2/html/emoticons/laugh.gif)

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

[ajracer]

Felix:

I'm an old school guy and not too sure "how to" do the digial audio thing ??
But if you suggest maybe my Camcorder and I could try that. Only problem now is
the vehicle is at muffler shop for some exhaust pipes, mufflers, etc. SO the sound
effects will be Much Much tammer than yesterday when we ran the puppy with the
open headers. LOUD, LOUD, LOUD you get the message, BUT also sweet.

Side note the cable clutch hook-up to the boxster tranny is not working as planned
so I will likely need to either adjust up-top or make some minor changes to get the
desired movement of 0.75" - 1" to disengage the kelvar clutch disc.

Update later. We should talk further once your audi / boxster setup is closer to
coming together.


Allan

[Dr. Roger]

Hi Allan,

Any progress on you LT1 914???? (IMG:http://www.914world.com/bbs2/html/emoticons/boldblue.gif) (IMG:http://www.914world.com/bbs2/html/emoticons/boldblue.gif) (IMG:http://www.914world.com/bbs2/html/emoticons/boldblue.gif)

I appreciate your resourcefullness and vision.

That thing is going to be so brutally quick and fast!

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

Heck, if you want to, send me a video tape and i'll convert it to a file and post it for you. (IMG:http://www.914world.com/bbs2/html/emoticons/wink.gif) PM me, if ya' want, for my address.

Roger

[ajracer]

Some photos for those interested.

Vehicle is now driveable and I have about 100 miles on the V8 - Boxster
engine tranny combination. The cable shifter is real sweet and precise,
but couple of minor items to sort out with the engine, clutch linkage, etc.
Diffinitely has some balls, and MY first time DRIVING any 914 !!! but this one
is easy to "fall in Love with"

Allan

[ajracer]

Another photo for Roger;

prior to installing into teener

[ajracer]

Another one for Roger

during tranny installation

[Andyrew]

Wow, looks nice.

How much did all the boxster trani conversion and clutch and everythng work out to be?

Sounds very interesting.

[ajracer]

Greetings Andyrew:

Let me see if I can give you an idea on the Boxster Tranny coversion costs:


1/ 2000 Boxster (traded alumium 915 tranny cost $1000) est $1,500
2/ Cable Shifter set-up (German Auto Dismantlers, Atanta) 275
(this included actual shifter, cables and linkage pieces)
3/ Clutch / pressure plate, (Kevlar disc; and beefed plate) 400
4/ Custom Starter set-up (gear reduction unit) 400
5/ Custom Flywheel/Ring Gear/Adapter Plate 1,500


In addition to above items:
6/ I converted to five lug hubs and am running 944 turbo c/v which incidentally
bolt up to the Boxster tranny. (special axle lengths were needed)

7/ Made my own tranny mount and hardware necessary to hang to unit off
the original 914 rear tranny mounts of the body. (tried to keep something
original with my baby)

I think that is about it ! So for arouund $ 4,000 I get a late model Porsche
tranny and shifter; coupled to my LT1 350 Chevy. I have only driven the vehicle
about five times in past two weeks BUT it shifts like a dream and goes like stink.
After I sort out the minor engine and clutch linkage issues I will then try to push
it a little harder. Thanks for your interst.

Allan

[BIGKAT_83]

Allan, The setup looks great!!! From the pictures with the car on the trailer,it looks like you are using ROH wheels. What size are the fronts?

Sure would like to see a picture or 2 of your starter setup on the transaxle.

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

[neo914-6]

QUOTE (ajracer @ Oct 9 2005, 06:52 PM)

5/ Custom Flywheel/Ring Gear/Adapter Plate                              1,500     7/ Made my own tranny mount and hardware necessary to hang to unit off    the original 914 rear tranny mounts of the body. (tried to keep something    original with my baby)

Allan,

The question for us V8 guys is how much to replicate the adapter and mounts for us? (IMG:http://www.914world.com/bbs2/html/emoticons/biggrin.gif)

I'm looking at gearbox alternatives (offshore) but I am already getting familar with the Boxster 5 for my Neo914-6 so (IMG:http://www.914world.com/bbs2/html/emoticons/idea.gif) your V8 adapter could be an option...

[Mueller]

QUOTE

6/ I converted to five lug hubs and am running 944 turbo c/v which incidentally bolt up to the Boxster tranny. (special axle lengths were needed)

944 turbo or regular?? (IMG:http://www.914world.com/bbs2/html/emoticons/smile.gif)

sounds like you got a potential market (IMG:http://www.914world.com/bbs2/html/emoticons/smilie_pokal.gif)

[neo914-6]

QUOTE (Mueller @ Oct 10 2005, 11:44 AM)

QUOTE 6/ I converted to five lug hubs and am running 944 turbo c/v which incidentally bolt up to the Boxster tranny. (special axle lengths were needed) 944 turbo or regular?? (IMG:http://www.914world.com/bbs2/html/emoticons/smile.gif) sounds like you got a potential market (IMG:http://www.914world.com/bbs2/html/emoticons/smilie_pokal.gif)

Good question, my '74/75 CV/axles fit the Audi 1.8 transaxle flange but they don't fit the (Audi) Boxster 5. Some say they are identical but apparently not...

I'd like to know the axle and CV parts details. Allan, are you running 914-6 stub axles?