Boxster Build Project

[zevenbergena]

Hello everyone-

It has been a long time dream of mine to build a car from the ground up- fab my own frame and bodywork and source parts for a very fun roadgoing, track worthy vehicle. Lightweight, simple, and raw are my visions for such an undertaking.

When it comes to sourcing parts, I want things that are relatively accessible, and not extremely expensive or exotic- ideally be able to drive down to the parts shop and get anything I need, or of course utilize our wonderful host.

Something that popped out at me as a potential project would be to basically construct a lightweight space frame, and use Boxster componentry for drivetrain and suspension, brakes, and other absolute necessities. Since I trust the factory quite a bit, I would plan on taking measurements off of a Boxster, and use the stock dimensions for engine/tranny mounts, suspension mounting points, etc.- basically convert a Boxster to a different frame, with weight and 'essentials-only', in addition to safety, being the main goals.

Has anyone done anything like this before? More or less a Boxster component build? It would be my goal to keep it under 1,800 lbs, get whatever power from a Boxster powerplant reasonably available, and destroy local auto-x and track events.

Input? Ideas? This is an extremely early point in the process, tossing around potential projects and such...

[Flieger]

Wow, sounds interesting.

That is a very ambitious project. I would like to see it.

You are blazing your own trail, though. Good Luck.

[Zeke]

You might consider using some of the Boxster chassis. I have no idea what body work you have in mind, but the box has AL hoods and the basic monocoque is not a lot more heavy than a bunch of steel tubing. Remember that these cars handle very well on relatively big tires, so the stresses are large. That will take a substantial tube frame to equal the stiffness of the box. If you remove every non essential part from the car, it will be light. And, it will be a lot easier to register with your state DMV.

[zevenbergena]

I honestly do not have a lot of experience in car building/fabrication, but I am very much planning on learning. Still kicking myself for never getting involved in SAE the first time I started college. Next time around, I will be doing as much as possible.
Off the top of my head, I was thinking aluminum alloy frame (this is without being totally up to par on material costs, strength of materials, etc) similar to what I've seen in other race car projects, fibreglass or carbon fibre bodywork, aluminum sheet metal bulkheads, interior stuff, etc. And like I said, essentials only, minimally street legal (windshield, headlights, working doors). Just seemed like it would be fun to take something already well handling and engineered like the Boxster or Cayman and take a thousand pounds out. I saw this on eBay:
http://cgi.ebay.com/ebaymotors/Other-Vehicles-Trailers_Race-Cars-Not-Street-Legal__Porsche-GT-Racing-Boxster-RSR-Worlds-fastest-Race-Car_W0QQitemZ320314457976QQddnZOtherQ20VehiclesQ20 Q26Q20TrailersQQadnZRaceQ20CarsQ20Q28NotQ20StreetQ 20LegalQ29QQddiZ2828QQadiZ2792QQcmdZViewItem?hash= item320314457976&_trkparms=72%3A727%7C39%3A1%7C65%3A12%7C240%3A1318&_trksid=p4506.c0.m245
Pretty much exactly what I'd like to do, slightly less prepped and on a slightly more modest budget, I read they have over $100K into the car and I found that slightly discouraging...

[mistertate]

That car was in the Autocross/Racing Forum 6-12 months ago. I bet if you search on some of the terms in the Ebay ad you'll find it.
If $100,000 seems like a lot of money then I don't think spaceframe cars are for you. Figure out what class a spaceframe Boxster will run in and find out what the average budget for that class is. If you'd done FSAE you'd know how much work goes into making a spaceframe.
If you want a fun "track/DE" car you can still do a lot with the unibody. The convertible weighs a ton. With a hardtop and a cage, removing the convertible you can easily get down to 2600 lbs. with driver. Almost all of the running gear is interchangeable with off the shelf GT3RSR parts.

[mikefocke]

I have doubts that you can engineer safety

into such a car equal to that of a stock Boxster. I've totaled a Boxster and I appreciate how well they crumple.

I'd also suggest looking into the track you want to drive on and talking to them about their rules. They may have restrictions on home-built cars because their insurance company insists on it.

I also can't see selecting any Porsche as a starting point as any parts you would need to buy are very expensive...even ones from a wrecking yard...compared to a Miata or the like.

[tarheelturbo]

if you want to build somthing like this and have no experience i would suggest a lotus 7 esque car. perhaps a westfield, caterham, or wcm ultralite, these cars can be put together at home, superlight, crazy power to weigh ratios, insane track performance, for the experience of putting something together thats meant to be like that, and it will more than fullfill the autox track needs of anyone, for a much more easy to budget price. theres a great forum you should check out. its usa7s.org theres alot of information there

[SandyI]

I know someone with a tube frame 914-ish racer. 350 hp. Weighs about nothing. He's probably got $150,000 in custom/fabricated parts in his car.

Out of curiosity -- How much do you have in your budget?

[rfn026]

Here's some inspiration. Bidding got to $19,100. I'm just guessing that's about half of what he had into it.

Richard Newton
Porsche Race Car File

[SandyI]

Spec Boxster series is really taking off here in So Cal with the POC. For less than $40,000, you can create a terrific track day car.

But taking those Boxster parts and creating a whole new vehicle that's going to kick butt on the track means outsmarting the engineers at Porsche. Good luck with that.