Gussets and crush tubes - Porsche 986 Boxster V8 engine swap track car build 5

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[@glennp9904]

I think u should put 2 gussets ar the front end of that engine cage also

[@BuiltatBlackjacks]

Your gussets are in the wrong place. Welding them to the face of the box section like that causes the face of the box section to flex and will lead to cracking. They ought to be welded in line with one of the two vertical faces, so they look like a lower case b or d in cross section and not like a lollipop. A folded U section that was welded to both sides but not to the faces would be much better.

[@Simey2wheels]

Exactly, the correct way is always in line with the vertical face of the box section. I'd imagine they will be quite thin wall too, so even more likely to crack as all the force is in a flat face.

[@confused47]

If what these guys are saying is right, an extra couple of lengths of the same box section might have made a better gusset? That would have picked up on the outside edges? Not quite as pretty, though... ;)

[@HomeBuiltByJeff]

That makes sense, but I am not really worried in this case. The square tubing I used is well and truly over sized for this job, but I will keep it in mind for the future.

[@bshusted]

The smaller alternator from the B5 Audi or VW chassis will fit the same mount and provide plenty of power for your needs. I would also recommend ditching the OEM active engine mounts for solid poly ones.

[@anomamos9095]

The way to improve the engine mounts is to bin the factory ones and use something similar to tough mounts. Basically a swing arm or leaf spring bushing in a bit of tube. I think you did it like that on the Alfa?

[@trapjohnson]

Oh me of little faith: I am guessing a socket has just enough room to get to the nut/bolt in between the two struts of the engine mount connection?

[@brentspang9092]

Jeff, aren’t those ANTI-crush tubes? 😂

[@andli461]

Please rethink how the front corners of the cradle (not) connect to the front mount/chassis in the shortest way possible. That is directly to where you have the chassis bolts if you see what I mean. (Gussets or separate bars may be the easiest to add and sufficient.) As it is now, you are loosing a lot of torsional stiffness. It’s also easy to think that the bottom bar help in that matter, but it won’t. But I understand why you added it. Great project and a respective pace. I really don’t want this to come across as a stupid rant, but as constructive input. Sometimes (read: always) it’s a good thing to follow “good engineering practice” even if “it’s sturdy n’uff” though. That’s what makes the difference in the end. Keep it up!

[@danielprivate7442]

lol...the way the tone of your voice slightly sinks every time you say "the wiring".

[@mclarenjohnf1]

That subframe is a work of art the dimples make all the difference.

[@craig7393]

Remember safety glasses when drilling jeff. Stay safe

[@88Frank]

As long as you don't put your eyeball next to the bit, I think you'll survive!

[@moonface978]

I don’t want to garner any hate but I think the music could do with a bit of an update

[@zenithenginering6099]

Also, Should be flush with the outside and inside of the rhs

[@GrindhousePerformance]

Better to be over engineered than under engineered. Looks good Jeff!

[@DiscoFang]

That's what I say to myself whenever I see cream donuts.

[@hopglenn]

Hi Jeff. This will be a great build. Even though I bleed VW, the fact remains that VW/Audi have had issues with timing chains, guides etc. Do you know the state of them in this engine? You may want to consider giving it a look before you bolt that baby in for good.

[@HomeBuiltByJeff]

That is why I got this early engine with a belt not a chain ;)

[@hopglenn]

@@HomeBuiltByJeff Ah, wise man.I didn't realize they still had a belts this late. Of course belts need service too. I guess you got that covered.

[@zenithenginering6099]

For best results when gusseted results the gusset should be flush with the outside or inside of the results, not in the middle. Placing them in the middle may look good but there is no support under the gusset. Similar principal to the crush tubes.

[@zenithenginering6099]

Sorry the auto correct stuff me up . It should be, When gusseting rhs

[@richardpierre7946]

Looking good! Any concern with the alternator or other close parts hitting the cradle when the engine moves under load?

[@stuartd9741]

Actually thinking about it Jeff could swap out the alternator for a smaller one if he doesn't use /junk some of the electrics?

[@NeilConnor]

No such thing as over-engineered.

[@delswanson3593]

Very cool! I'd add corner gussets on the bottom as well it looks like there is room.

[@Driven-daily]

Those welds are looking GREAT on the subframe! Swapping that alternator might be a challenge in the future; It's probably a good idea to toss a fresh one on now while it's easy to access.

[@fredericrike5974]

Lookin' pretty good, Jeff! I'm thinking the wiring might not be such a bear- you have been planning this as a track car so running the engine on a Haltech stand alone computer should be very workable. The engine was attached to an auto trans in the Audi, so that controller is not going to work and I don't recollect it to be very tunable either. All that's left is a pretty basic car wiring job- lights, brake lights, fuses, ign switch and power lead for Haltech. The Haltech will be taking all your engine sensors and will drive a digital dash- you can take all the Porsche gauging out and happy days! I think the vernacular for this is"You've got this"! When you first sprang this i thought you'd gone around the bend, honestly- I mean a V8 in a Porsche Boxster! then again the ubiquitous LS has been put into a 911, so maybe so. Then you did it, and gee willikers- it fit! You probably won't have anymore trouble with the wiring than the Alfararri- which you have know from day one will be mostly scratch. Best to the Missus- FR

[@FredLarracuente]

Awesme job Jeff! Question, can you get to the upper mount location through the access panel inside the cabin? It may be easier than from the bottom. No Mrs. Jeff today? Cheers from Puerto Rico.

[@DiscoFang]

Just adding a comment here to say you should have done _________ differently. (Fill in the space as required per standard comment here.)

[@garagechronicles9008]

Looks good, sir. Garage Chronicles by Grant launches tomorrow. I.m a bit fan and will send you some swag shortly. Great build, jeff!

[@nathanaeljonesmyfsd]

Can't help but wonder if this could be built with some roll cage-style round tubing and less welding. I'm not certain that ~1 inch (or whatever) box tube is going to be strong enough

[@mvlad7402]

Great idea! I'm thinking about plug Tesla engine into some Porsche.

[@jiminycricket9877]

I really enjoy your vids and the way you approach the different projects. On this one though I would question why you’re keeping so much standard? For a track car why not bin as much as you can - simplify and add lightness - plus get some itb’s and proper exhaust manifolds to free up some horses? You’re going to a lot of trouble to make the car a bit better, it wouldn’t take much to make it a bit of a beast. Sound better too. Cheers and keep up the good work.

[@Mr_Spegru]

Such a great project - fabrication on a modern car. Mind you if it were me, rather than square tubes for the engine mountings I'd have used two pieces of flat plate (Cardboard Aided Designed of course) that also extend around the side of the tubes going further out to more of the round plates. Would be easier I think. I also liked the dimple dies!

[@theimprovementsguy8871]

Looking good Jeff. I wonder if a square metal baseplate would of been better instead of the circular one. Just to allow a little more room to work on and could of over engineered that part as well lol with bigger thicker tubing

[@bobstacey9311]

Saw the make the noise tee shirt and thought not seen any binky bracketering in a while but your engine mount gussetering more makes up for it

[@stuartd9741]

Exactly! Been a bit parched in the Binky front - understandable. Jeff certainly makes up for it. !

[@bobstacey9311]

@@stuartd9741 we were spoilt with the weekly 500 quid race car updates, but back to the glacial drip feed once more, who are we to complain though?

[@kowkes]

I'm just noticing that you sorted out your plasma cutting issues. What was the issue?

[@witchcraftauto]

This is so awesome, where did you learn to weld? I really want to learn that skill

[@jubiletabustamanteserrano2446]

EL SUBCHASIS ESPECTACULAR AMIGO . LOS CUADRADILLOS DE LOS TACOS DEL MOTOR UN POCO CHAPUZA ES MI OPINION

[@josipperinic1823]

Great project have nice 😷froam Croatia

[@JVR_Funwithdesign]

Great work. Maybe 'over-built' vs 'over-engineered'... 😉

[@bnambisan]

What about closing up the open ends of the tubes?

[@Brendan.Wheatley]

I've only driven a Boxster once and I welcome the upgrades! Cheers for sharing mate!

[@Meyersmanx1]

Hell yes, engine in! Congratulations matey.

[@patfilice]

I would use some flat plat to the upper mount

[@jimclarke1108]

Interesting to see the V8 in a Porsche 911 style

[@fractalrender]

Also think you should put gussets on the front section since it tends to tilt and may cut the welds by stress. You should have a triangled weld. It looks strong but the engine torke is a lot of twisting force o one single weld. That thing on the front will eventually crack. You can put to triangle plates on each side. Cheers!!

[@stuartd9741]

I was thinking same. However if you look closely the centre V is welded to a square plate about 5 inches (a guess) It is loaded up in the centre but does look quite strong. I'm also wondering if the subframe is too strong without any flex it may crack anyways. So a little flex at the front might be a good thing considering this is a track car....

[@johnbroman7235]

With the engine mount-to-subframe studs at an angle, how will you separate the mounts from the subframe?

[@DiscoFang]

After unbolting the top of the mounts from the engine and raising it.

[@joejuska5390]

I like that you use full PPE

[@hotdognr12323]

Have you looked into using the hydraulic actuators in the factory engine mounts? As I understand it you can control the stiffness of the engine mounts, but they default to soft and "comfortable" when unplugged. I can't wait to hear her start up!

[@HomeBuiltByJeff]

I haven't. I was wondering what the plugs were for ;)

[@hasbeengood]

Nicely done, I like it!!

[@neilmchardy9061]

In the uk we would cap off all those tubes because of salty water ingress.

[@HomeBuiltByJeff]

No salt on our roads much less on our race tracks ;)

[@neilmchardy9061]

@@HomeBuiltByJeff rusty car central over here

[@DiscoFang]

On the KZbins you cap everything, weld perfectly, gusset to perfection and in fact DO everything as if the fabrication guru of the ages ... because of salty comments. (Not your comment, it just seems de-riguer for this comment section. Just saying it here for the salty pun of it.)

[@neilmchardy9061]

@@DiscoFang I think your cassette tape has got tangled round your capstan, you stick a pencil in your hole and tighten it up. Glad to be of help.

[@DiscoFang]

@@neilmchardy9061 Thanks! The old road-trip tune up. I needed that.

[@MozMozzie]

Cut a panel where the back seats are to get access to the back of the engine

[@HomeBuiltByJeff]

There already is one ;)

[@brownah]

Gahhhsset

[@robertmorales391]

Can’t wait to see it running Jeff.. nice work...hope you guys are done with all the flooding. All the best from Miami...

[@robwhite240z]

A nice set of 4 in to 1 tube headers would be nice.

[@HomeBuiltByJeff]

Just using the stock manifolds for the time being.

[@richardhintonracing]

I thought this really was a project too far - I have to say I am proved wrong it is hugely impressive and that surely is the biggest obstacle over come . Thank goodness I don't have to marry up the wiring that is the stuff of nightmares on two modern cars . So far very well done and it will look factory when it goes in for the final time - that may take a while yet . Taking on all this scary stuff must be all to do with going in to a blazing building . 30+ years on from you now we all get a bit more risk averse !!

[@kyleschenck308]

Finally the engine is in, moving along nicely. Love the video's. Cheers from South Africa 🍻

[@seanwalsh999]

Hey Jeff I went over to that other channel you suggested, and that seemed like a nightmare, you have done the easy part , I think that guy is still trying to figure out the wiring. Hope you have better luck.

[@1one3_Racing]

Hey mate, I was going to pin you in a Carrera frame for $2500 that popped up on Facebook yesterday. Seemed right up your alley!

[@realmac3443]

I love all of your builds! Keep up the great work. I hope you make the boxster look mean!

[@DiscoFang]

Just want to say that whatever you may think of content that the audience is interested in, this is the most engaging build you've done since the early days of the Porsche.

[@pascaljeske7307]

Wow great Job Jeff and cool Video thank you ❤️👍❤️

[@tailormade6470]

I bet you could sell those engine cradles. I know someone that will buy one for sure! Not to mention a how to wire it in guide!

[@spagooter7901]

Nice work Curious as to where you got your band saw? Looking at getting one myself

[@Biwaqu]

How Jeff says here almost sounds like the german version hier

[@ToasterCoasterAdventures]

lookin good, you just need to make another for me haha, altho I think I tossed my engine mount brackets out...

[@martysbricks328]

Great T-Shirt, probably the best fabricators ever :)

[@StevenAndrews]

It’ll be running by the weekend, no problem.

[@myturkishlife1777]

Nice video Jeff.. Just a thought on the last engine mount... Is it possible to make the remaining engine mount on another part of the engine, if the function is to stop front to back movement maybe making up a mount in a more accessable place might be easier... Cheers

[@stuartd9741]

I'm thinking extending the front mount higher up attaching to the body at the top. Easier access.

[@ivancordero6521]

Spanish coment 😉😉😉

[@nickmassey9104]

Well done with the subframe /brace could you fit a plate mount up above for the front mount .

[@stuartd9741]

I was thinking the same. Extend the mount higher up don't look like a lot of room there + easier disassembly.

[@wesleycardinal8869]

See ya later fabricator.

[@stuartd9741]

Lol like that 👍

[@svenT16]

Good One 😂👍

[@Noq850]

Is the metal always coated you get? looks like there´s paint on them. sorry for the bad grammer greetings from germany

[@8700s14]

Seems to be the most commonly available shs over here in Australia (the blue painted variety)

[@Noq850]

@@8700s14 thanks for the info

[@nicolasecheverri525]

This is going to be epic! Newbie question: why do you weld the gussets in three separate parts instead of the whole contact point with the frame?

[@HomeBuiltByJeff]

That is enough to do the job.

[@robshipman8691]

@@HomeBuiltByJeff Done like that if a crack starts wont run full length of weld all the way down the gusset...

[@mawe42]

Will you be able to remove the engine mounts from the cradle or is the plan to unbolt the engine from the mount?

[@HomeBuiltByJeff]

They are all removable

[@mawe42]

@@HomeBuiltByJeff I guess you only do that misstake once, but had to ask! 😁

[@timwhalan6417]

👍🏻🍺👏

[@mrapex1182]

Off of?

[@DiscoFang]

Isn't English an utter delight? Get off; get out; get out from; get off from; get out of... but... no get off of? It's discrimination!

[@johnrb9397]

With respect why not get a proper track car and spend the extra time with your wife and family?

[@mymotorbikeobsessions]

I’m not sure about Jeff, but for me quality time with the family comes if I can get some time spinning wrenches on my motorcycles. Everyone has their own way of getting rid of the stress of life. If I can decompress in the garage and maintain balance with my family time, I’m a much better person overall.

[@MrKombiman]

Exactly this. I have a very head heavy day gig. Some 'grease times unpacks my noise and let's me meaningfully engage with my family. Sometimes my boys help and they learn too. This continues the process like I learned with my dad. Often its about the journey and how it flows rather than just the destination!

[@janeblogs324]

John mustn't be an aussie. We spend 95% of the time building our cars. 10 year builds are common But clearly Jeff enjoys building cars

[@confused47]

Jeff works shifts as a firefighter, Mrs Jeff (from what I can gather) works a "regular" 9-5 job. This means that Jeff has a couple of days a week at home, alone. They also spend time together doing the "Fun Facts with Mrs Jeff" segment, and they've been married for 10 years now, and look to be stupendously happy together and with their lifestyle. I'm sure there's plenty of quality "family time" for them both of an evening when Mrs Jeff is home from work and Jeff is finished in the garage for the day! This is his hobby (and a source of extra income), and enjoys the process of the build, I'd say probably moreso than the actual end result! ;) He set himself a challenge with this vehicle, and is working towards it. Much more satisfaction doing this type of thing yourself than buying someone else's project (because even a dedicated "track car" like a Lotus, Caterham, Radical, Ginetta etc are all just "someone else's project" that's been sold off to make some money back)

[@stuartd9741]

I get your comment but how many V8 Audi/ Porsche track cars do you know exsist? It's all about the engineering challenge - if one is technically minded. Quite easy to go buy a track car Nothing like building your own and enjoying fruits of your labour.. ... It at least departs from the Lamborghini project cars nearly every other YT channel has these days....