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First start

Hey guys,

once again, I apologise for the lack of updates recently, I’ve just been really busy trying to get this thing finished. On Friday I started the motor for the first time with no major issues. The starter and fuel relays had to be jumped, which is something that I still need to figure out. I have to spend the next few days cleaning up the wiring, making hard brake lines, and mounting the hand brake. There will be much more detailed updates in the next week or so. I apologise for the bad video, but I honestly wasn’t expecting it to start the first time. I shut the engine off quickly because I thought I heard some noise and then my phone died.
 

First start up #porscheV8 #boxsterV8 #rollingshell #boxster #garagebuiltcars #porsche

A video posted by Boxster LS (@porschelsx) on

Throttle Cable

Many people will tell you that the stock throttle pedal/cable will not work for the V8 swap, but what most of these people don’t know is that the early Boxsters came with a full cable setup (no drive by wire). I purchased mine from a 986Forum member with a pedal for $50. The cable length is great and the TB travel is spot on. Today I made a custom bracket to hold the cable in place. The clamp that comes with the wire can be attached to one of the intake manifold bolts to hold it in place. The end of the cable has a metal sleeve that flares out at the end towards the TB. I used small metal plate to wedge the flare to the bracket (you can see it below held by two stainless machine screws).

 

Water Pump

Renegade recommends using the Meziere water pump with their kit, but I decided to go with a local manufacturer called CVR. Their pumps are a little cheaper, but the build quality is still there. I’ve seen this pump used on other 911 swaps as well. The inlet/outlet orientation of this pump is not ideal for the Boxster, and given another chance, I’d probably go with the Meziere setup. I got an extra engine mount bracket with my Renegade kit (no surprises there…), which works out great as a pump mount. Below are some pictures of the bracket. Once I have the complete cooling system figured out, I will post more pictures of the pump location and hose routing.

CVR Remote Electric Water Pump

Bottom of the bracket. I’ve seen welded the seam.

Alternator

I got my hands on a nice AD244 145 Amp alternator at a local scrap yard which I was planning to use for this build.┬áThis is an alternator that came on some GM trucks in the early 2000s, and it’s a very popular upgrade for the LS1 guys. I made a bracket for it to match the new harmonic balancer, but once I put the engine in, I realised that it wasn’t going to work. The mounting bracket on this alternator is just not ideal for this build. It would take a lot of modification to the alternator body in order to make it work, which I wasn’t really too keen on doing.

AD244 145A alternator

The original Porsche alternator on the other hand is a pretty easy fit. Renegade sells a bracket for around $140, but I think you can make one yourself in an afternoon with some scrap metal. The front bracket mates directly to the block and requires a spacer to align the pulley with the harmonic balancer (you will also need to file down the block in one spot where there is interference). The rear and the top brackets require a custom mount. Save yourself some trouble, and make the bracket while the engine is still out. Below are some pictures of what I made. These are not the finished product, I still need to buy proper bolts and give it a coat of paint.

Stock Porsche Alternator