Andrew.M.Cox

I started a thread at 986forums, then found you guys here too. So I'll catch you all up.

Spec Boxster Build, the beginning of about a two year projected timeline. I don't have clearance to race until our youngest (3 month old) is at least two. And that gives me a comfortable timeline, around work and family life.

Donor: 1998 with 107,000 miles

Replace bearings in Upper, Lower, and Tensioner pulleys with 6203 bearings.

<a href="http://s1325.photobucket.com/user/roosnuts/media/98%20Spec%20Boxster%20Build/IMAG0205_zpsgq7i8uog.jpg.html" target="_blank"><img src="http://i1325.photobucket.com/albums/u635/roosnuts/98%20Spec%20Boxster%20Build/IMAG0205_zpsgq7i8uog.jpg" border="0" alt=" photo IMAG0205_zpsgq7i8uog.jpg"/></a>

Using the outer race from an old bearing, cut with a dremel cutoff wheel, all the way through. This will allow the old race to be used for pushing in the new bearing and allow for easy removal of the old race from the pulley housing.

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Using a vise as a bearing press.

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Window glass and regulators removed. Next, I'll pull the wiring and cut off the extra metal in the door panels. Dash is ready to pull, except for the one t20 bolt that my short bit can't reach inside the headlight switch/****. I do have a long bit, but that's for something else.

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Dash is out! Ignition housing is out, now I've got to cut off the steering lock. FYI, I found that removing the ignition housing requires depressing this little nub. It took me a little while to figure that out.

After steering lock removal and possibly updating the ignition housing with the newer version, it's time for wiring clean-up (nightmare) as the cage is likely going in next.

<a href="http://s1325.photobucket.com/user/roosnuts/media/98%20Spec%20Boxster%20Build/housing_zpsatd3tuqi.png.html" target="_blank"><img src="http://i1325.photobucket.com/albums/u635/roosnuts/98%20Spec%20Boxster%20Build/housing_zpsatd3tuqi.png" border="0" alt=" photo housing_zpsatd3tuqi.png"/></a>

<a href="http://s1325.photobucket.com/user/roosnuts/media/98%20Spec%20Boxster%20Build/dash_zpswj3w5qdz.jpg.html" target="_blank"><img src="http://i1325.photobucket.com/albums/u635/roosnuts/98%20Spec%20Boxster%20Build/dash_zpswj3w5qdz.jpg" border="0" alt=" photo dash_zpswj3w5qdz.jpg"/></a>

mjj0000

The build will go much smoother if you start by removing the windshield.

Also, I recommend removing the engine and trans and all the underbody pans prior to starting the cage install.

I also have some pointers on how to go about the wiring. PM me.

Andrew.M.Cox

Thanks mjj for wiring help. PM sent. Yeah, getting window out is next on my list. How does engine/trans removal help with cage install?

Andrew.M.Cox

Any thoughts on using an expired seat with a BK seat back brace? Is there even enough room between the seat and engine?

mjj0000

You are on track. You will be amazed how much electronics you will remove. As you do this, be sure to frequently check that the car still runs. It is easy to mess up the immobilizer. After removing the extra components, I traced every wire through the harness to the fuse box (or other termination point) and cut the wire as short as possible. I left the pin as I didn't have the proper tool to remove those. Keep all the power wires (red/blue, red/black, etc.) full length. These are very useful for the many accessories you will add.

I mounted the cool shirt control in the passenger air bag dash cover and made a custom panel for switches that goes where the radio and heater controls were previously located.

There are few good options for mounting the kill switch. My kill switch is mounted to the small piece of plastic that covers the wiper mechanism (between the hood and windshield). The plastic is kind of flimsy, so I reinforced it with fiberglass. Avoid putting it in the hood as then you need to worry about the wires moving every time you open it.

My immobilizer is still under my seat. I have several drain holes drilled and have wrapped the electronics in plastic for insurance. I've driven through monsoon level storms without problems, but YMMV.

Here is my list of extra circuits:

1. Power supply for a transmission cooler pump
2. Extra wiring for a transmission temperature gauge
3. Extra wiring to kill the DME relay (kill switch)
4. Power supply for a cool suit pump
5. Power supply for a video camera(s)
6. Power supply for a auxiliary defroster fan
7. Extra wiring for an oxygen sensor readout
8. Two way radio

mjj0000

I am tall (6'4") so my seat is right up against the cage.

Dave DE

If your seat is within 3" of the rear firewall you can use FIA padding rather than a seat brace.

Andrew.M.Cox

Yeah, I was thinking about that padding of firewall approach. I'm at least 2 years away from racing again, though I might DE a little before then. So I was thinking of buying a used seat cheap and hopefully not having to buy a new one later. I guess won't know how much room is there until I get it in the car. I'm 5'8".

Dave DE

My guess is your seat will be a bit more than 3" away.

Andrew.M.Cox

How are people mounting the dash? My buddy had some aluminum end caps made for the dash and those mount directly to the cage. So are most builds removing the bar that the dash is mounted to for weight reduction?

jdistefa

^ That bar ties the a-pillars together and also is a handy point to attach a center triangle net to. Suggest you leave it in.

Andrew.M.Cox

I'm thinking about buying this used 2qt Accusump system I'm usually a little hesitant to put anything used in the oil system, but Canton offers a rebuild/clean/pressure test for $60. And I could clean the spin-on adpater myself, but what about cleaning the lines and fittings? Any thoughts here?

HoBoJoe

For a used system you'd want to send it off to have it cleaned and replace the lines.

There is a brand new one 4 posts down from this post: https://rennlist.com/forums/spec-box...-for-sale.html

Andrew.M.Cox

After removing the ignition housing, the little steering lock nub was exposed. Off you go!

<a href="http://s1325.photobucket.com/user/roosnuts/media/98%20Spec%20Boxster%20Build/Screen%20Shot%202016-01-23%20at%208.54.46%20AM_zpshy8rfzkp.png.html" target="_blank"><img src="http://i1325.photobucket.com/albums/u635/roosnuts/98%20Spec%20Boxster%20Build/Screen%20Shot%202016-01-23%20at%208.54.46%20AM_zpshy8rfzkp.png" border="0" alt=" photo Screen Shot 2016-01-23 at 8.54.46 AM_zpshy8rfzkp.png"/></a>

Andrew.M.Cox

Does the little plastic wind deflector thing stay in place? Seems like, if nothing else, the car looks better with it in. Also, the rules don't mention that windshield wiper motor can be removed. So does it need to stay in?

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