Back Yard Boxster Build

[hosickjg]

So as some of you may know I have a 99 Boxster with a destroyed number 6 cylinder. I bought a block to build but found it had a bad IMS bearing and ended up having to split the block and rebuilt everything.
Thought I'd make a post showing that it is possible to build these engines in your driveway and there are many SIMPLE and CHEAP things you can do rather then buy those expensive Porsche tools. Spend the money on upgrading the engine instead!
The engine I'm building has many upgrades like a LN Engineering IMS bearing, etc, etc.

Bearing Assembly assembled and installing the IM Shaft:



Bottom 3 pistons installed with the connected rods torqued: I used a piece of galvanized pipe, a couple washers and an old head bolt instead of the specialized Porsche tool to properly locate the bearing assembly in the block:




Assembled the block halves and installed and finished 2 pistons:



Aligning the connecting rod before installing the piston. Used a piece of threaded rod with 2 bolts locked against each-other to back up against the wrist-pin. Then duct-tapped the threads to make it just snug enough inside the piston pin:



Installing the pistons into the number 2 sleeve carefully so not to move the rod:



Installing the wrist-pin clip. I used a piece of galvanized pipe that I cut to size and cleaned the galvanizing out of the inside, then used an extension and a 15mm socket to drive the clip into place. It takes a bit of feel to do this but its easy and do-able:



There are many more to come. One head is on and timed, I'll post pictures of the tools I made for it.

All tools I made cost less then $50 and bought all stuff from Home Depot and Canadian Tire. Had to use a welder to make the cam holder. (have one).

[BYprodriver]

Good for you I hope it works out! Is your old case half beyond LN Engineering help?

[hosickjg]

Nope, the old block is fixable. I plan on running the engine I'm building until it gives up and then sending the old block to have 'Nickies' put in it. The $4000 is just not in the cards right now.
HOPEFULLY the block I'm doing right now will not screw up though!!!! EVER!!!!

[hosickjg]

Plus I figure this is good practice for when I'm building a much more expensive LN Engineering block!

[Wayne 962]

Cool, neat post. I'll probably "borrow" some ideas from you when I do the engine rebuild article / book on these engines!

-Wayne

[hosickjg]

Be my guest Wayne. I finished timing the heads last night and got the intake on. I will finish up the wiring on Saturday and hopefully get the motor most of the way into the car before I have to go to work (fingers crossed).
When I get a chance I'll post the photo of the rest of the tools I made to time the head.

[Zeke]

I want to be the first notified when the motor fires up and performs flawlessly. Making tools by improvisation is a great talent. Hats off!!

[hosickjg]

Got the engine in the car yesterday. Transmission and Exhaust on today. Tomorrow I will add coolant, oil, power steering fluid and brake fluid (clutch). Hopefully fire it up tomorrow!!!

PS --> I broke the bleader on the slave cylinder and after removing it relized its made a plastic!!!!! Plastic!!!!! Its an expensive car!!!!!! The entire F*&$&#ING slave cylinder is plastic!!! Does Porsche know what happens to plastic after 10 years!!!! IT BREAKS!!!

Anyways, picking up a new slave cylinder in Toronto tomorrow afternoon. Hopefully thats the last touch and it will be on the road again.

[JMatta]

Does Porsche know what happens to plastic after 10 years!!!!

The way they've cut corners on the modern cars, one would wonder if they really care?

I wish I had the talent you're showcasing here...great ingenuity!

[Schumi]

Plastic is lighter than aluminum...

[Wayne 962]

Yup. Well, it keeps people like me in business when they make more stuff out of plastic.

-Wayne

[hosickjg]

After many, many, many frustrating hours of work the engine started!!!!!!
Had some issues after getting it in including needing to replace a Crankshaft Position Sensor and clean up a ground but all is well now.

I think I would rather sell this car as a rolling project to someone else instead of do this again!!!!

[BYprodriver]

Congratulations! It has to get easier/faster the 2nd time.

[hosickjg]

BYprodriver, it scares me that you have done this more then once...... I hope you own a shop.