Porsche / Tesla FRANKENROADSTER - Motor Swap

[@goatk1]

Working on my PE. Testing for my PMP this summer! MBA not sure yet! Love to see engineers still engineering!

[@repairs101]

Rock on!

[@repairs101]

Terry says: Thanks for watching!

[@Helpsmallbusinesses]

you made everything look so easy. Looks like a fun ride!

[@repairs101]

Terry says: Thanks for watching the video. The project was fun to execute and even more fun to drive.

[@ckafam]

Great video. Thanks. Looking forward to 0-60 times and useable range. Enjoy!

[@repairs101]

Thanks! I'll get back to you when Terry has some data to report!

[@repairs101]

Terry says initial data suggests 1km per volt and 0 - 60(mph) in +3 seconds.

[@porscheoscar]

Do you a website? I've owned a 2000 Boxster S for 20 years this month. I dumped a ton of money into it. I barely drove it during the pandemic as I had to leave the state to take care of a family member. I would have sold it buf the idea of a electric motor conversion on a mid engine roadster seemed so perfect. Range was never an issue since I never drove it more than an hour. I did autocross the car a few seasons when it was still under 30k miles. Actually it was the most reliable car I'd ever owned for the first 70k miles which took me about 8 years to rack up. But then came those repairs. $5K clutch, IMS upgrade, T stat, motor mounts, $4k suspension (twice CITY ROADS!), $4k exhaust and headers, the $1k water pump every x miles, starter, alternator, AOS, etc... I told myself if the engine EVER died I'm NOT swapping for another ICE engine.

[@repairs101]

Thanks for reviewing the video as the conversion was fun to do. I don’t have a website for EV conversions. I got most of my technical information from the Open Inverter openinverter.org/forum It showcases many EV builds including my own “Another' Porsche Boxster/Tesla EV conversion”. I followed “Boxter EV” who started his build in 2019. Let me know if you need more information. Terry Moore

[@EVBoxster]

Well done. 👏🏻 You need to put the frame bolts the other way round (nut on top).

[@repairs101]

Received in my inbox: Hi It’s an absolutely great conversion. I’ve got a Porsche like that and I’m wondering if there is a guide for non-engineers with what and how to do and which parts to use. Thanks. Tom

[@repairs101]

Reply to Tom: There are lots of similar conversion out there. The video is a high level summary of what was done to this car. I have fully documented the tear-down and build which could be used as a guide only. Each build will be different because of the individuals choices for the electric motor, battery, control strategy, brakes, steering, etc. I may be able to put this into a PDF and offer it for sale. Terry.

[@endostyle]

@@repairs101 I would be interested in that a "guide" as well. I would like to convert the 2007/08 Cayman S. Most everything should be the same right?

[@repairs101]

You can reach Terry directly at : mooret88 at outlook dot com

[@davidvalentine3630]

how has the car been over the last 2 years ? update video ?

[@repairs101]

David: Just saw your email a few minutes ago. Sorry I didn't see your Fb message but I almost never use Facebook (other than for promoting my latest work to the few Fb followers I have. FWIW I'm a KZbinr so if you want a reply from me this is where you write me. Anyways I passed your message on to Terry (my neighbour and the creator of the FRANKENROADSTER) and he will answer here through me in all likelihood (remote possibility he will contact you directly). It has been 2 years already - the Roadster currently has it's wheels off for some upgrades and some fit 'n finish - and yes there will be a follow-up video this spring showing a motor bearing re&re. some modifications and some serious ZERO to Sixty action shots.

[@repairs101]

Received in my inbox: Ok that was absolutely fantastic. I grew up with a chevelle convertible when I was younger and recently I have purchased an older miata to fill that void. Great car. But my wife has an 28kwh ioniq electric and moving towards a second EV for me. Maybe the best of both worlds as no one makes an electric convertible. Really curious about it. What would be the cost to in materials alone? Batteries, tesla motor, mechanicals etc even a high cost estimate to do something like this? Any words of wisdom? I am in Vancouver as well. Great build Thanks! Elvis D

[@repairs101]

Reply to Elvis D: “So you want to convert a Miata to EV? The costs would be dependent on what components you want to put in the car. I have a Tesla LDU (Large Drive Unit) in the Boxster but I think you would need to go for a SDU (Small Drive Unit) or an Model 3 motor due to space limitations. The size and type of battery would be your next consideration. Batteries over 300V give you better range, but take up a lot of space, so you may need to sacrifice range for what you can fit in the car. The Boxster EV with a 400V battery can get around 130KM on a single charge. I’m guessing you would lose the use of you trunk to battery storage. BMS ( Battery Management System) and a suitable charger would also be needed. There are limited used EV components in Canada so you may have to buy new ($$$$). Used parts are more available in the USA but getting them across the border can be challenging. I have purchase parts from the USA, Canada, England, China and Spain. Parts alone for a good Lithium-Ion EV conversion will be north of $35K. I don’t want to discourage you as it was a great project, but it wasn’t cheap. Let me know if you need more info.” Terry M.

[@elvisd8832]

Sorry I couldn’t cut up the miata. Actually I was interested in the Boxster as the swap. Definitely more bolt in that any small miata.

[@dirkbergstrom9751]

Nice.

[@repairs101]

Thanks!

[@StephenHeizer]

Thanks! Very informative video. When you removed the clutch master cylinder, pedal and tubing, how did you plug the clutch supply line from the brake fluid master cylinder?

[@repairs101]

Sorry for the delay - Terry is out of town. You can reach him directly at : mooret88 at outlook dot com

[@esterpka817]

I want to do this to my E30 with a model 3 motor, any advice or websites that can help with instructions? Thanks Eddie

[@repairs101]

“Hi Ed. I’m glad you enjoyed the video. It was a fun project to do, and the end result is excellent. I can be a sounding board for you, and I suggest you look at the EV Open Inverter Forum. www.openinverter.org Lots of good projects and advice there.” Terry Moore [e-mail]

[@johndollarhide2574]

I've sure you have heard, but all Boxsters and 911s from this era will need engine replacements eventually, is there any reason this KIA/tesla setup wouldn't work in a 911? Is reversing the motor really just swapping the FWD and REV switch? Did you use the boxster throttle? I have the last year of cable throttle in my 911 and would have to use a cable converter of some kind right?

[@repairs101]

Sorry for the delay - Terry is out of town. You can reach him directly at : mooret88 at outlook dot com

[@pavlos4852]

Hi do you have the details for F1 moto in the uk

[@repairs101]

F1 Moto - [e-mail] Contact name is "Neville". (tell 'em Terry from Vancouver sent you)

[@geniustechnology3358]

Good luck

[@jonk8337]

Congratulations on your build. I’ve been dreaming about this swap for years. I really think the Boxster is a perfect candidate for this kind of EV conversion. I’ve been looking for a used first generation Boxster S to purchase for this purpose. What range are you getting?

[@repairs101]

Hi Jon. Thanks for watching the video. Yes, the Porsche Boxster & Boxster S is a prime candidate for conversion. The problem will always be finding one with a trashed motor but the body and suspension are still in good shape. I lucked out! As for mileage, last summer I was tracking around 100-120KM (60-70 mi) with a full charge. The range is dictated by the batteries you choose. I chose the KIA 400V batteries because they were the most compact high energy density air-cooled battery on the market in 2015. My battery/motor configuration allowed me to kept the Boxter front/rear weight ratio. The water cooled Tesla batteries has a higher density (longer range) but are too large to fit into the area vacated by the motor, tranny and exhaust system. With semi-solid state batteries coming into the market, I will probably upgrade the batteries to extend the range. Let me know if you have any more questions. Terry.

[@jonk8337]

Thanks for your reply. The 1st gen porsche boxster makes the most sense because of price and practicality. One can get one for cheap. No need to upgrade your suspension, brakes, etc. to accommodate the high performance EV motor. You are a pioneer in EV conversions. I imagine this is was how it was back in the early “hot rod” days. I see a future of building a custom EV car from one’s imagination. Now that we have 3D printing technology. I’ve already seen ready made “skateboard” EV platforms for EV cars at the SEMA shows. I can already see a private car maker emerging just for this market. Imagine 3D print a HotWheel and making one into a full size automobile.

[@jonk8337]

Hello again. Just wondering if there are any updates on your ev Boxster build? I am in the market for a 1st gen Boxster. I want to buy one with low miles and drive it til I decide to do the conversion. Any info would be greatly appreciated. Thanks for your videos.

[@repairs101]

Coming soon - Terry and I are collaborating on an update video showcasing some routine maintenance (bearings) and some upgrades (frunk upholstery) and MORE!

[@Andy-zv4gj]

What did you do for the trans a conversion kit? I have an 06 forester that i want to convert while retaining the 5 speed i’m assuming i need an adapter and gear reduction?

[@repairs101]

I forwarded you question to Terry. His reply: I never intended to have a transmission in this conversion. I designed and built a drive hub adapter so the two motor output shaft bolts directly into the Porsche CV drive shafts. The Tesla motor can rev to 18,000 RPM. The Tesla Motor “Package” has a built-in Inverter and a 9.95:1 gear reducer, so the maximum rotation of the wheels will be around 1,800 RPM. On my car, this will give you 120 MPH or 200 KPH. With the huge torque from the Tesla motor, the possibility of breaking a tranny gear shaft along with the loss of efficiency of a transmission, I would not put one in. I can change from Forward to Reverse with a switch in the cab.

[@Magicinstalls]

He doesn't need a trans converter kit. He did this the right way he got rid of all the original dry train, so not to put a drag on the motor and be inefficient. Everything Tesla.

[@KTporsche]

you can even make these kits to sell to public and probably and make a huge huge profit. just saying

[@SHaDoRuN]

What was the cost for the conversion? How fast is it compared to the original boxster ?

[@repairs101]

Hi Ken. Glad you enjoyed the show. I don’t know what the top speed is yet. I have had it up to 160 KPH (100 MPH) and it really wanted to go faster. Top speed of a normal ’02 Boxster S is rated at 260 KPH or 160 MPH. 0-60 MPH should be around 4 sec with the electric. The normal ‘02 Boxster S is rated at 5.5 sec from 0-60 MPH. As for costs, I am under $40,000 CDN, including the car. I am reusing old parts for the build. It would be substantially more if I had to buy a new motor or battery pack. Terry.

[@KeithParadise-g4r]

@jonk8337 I have a 2003 Boxster S with a bad motor.

[@repairs101]

Everybody's going to want to know: where and how much?

[@miguellavin5041]

I own a 1998 Porsche Boxter 986, How much would you charge me to do the conversion for me??? Have a Blessed day.

[@repairs101]

You can reach Terry directly at : mooret88 at outlook dot com

[@repairs101]

Terry's reply: “Hi Migel. A lot depends on where you are”

[@4literv6]

If you change the header to tesla swap or tesla conversion? You'd get a lot more views on this killer project. 👍🏻😎

[@repairs101]

Thanks for the tip!

[@4literv6]

@@repairs101 sure thing, can't wait to see more on this project. 👍🏻

[@repairs101]

I took your advice and changed both the Header and Thumbnail. Wish me Luck. I worked hard on this one. And thanks again for the tip!

[@KeithParadise-g4r]

Haven’t set a price. Alabama

[@KTporsche]

oh yeah and what is the range? haha that's probably the most important thing. I remember seeing a similar video and the guy got like 120 miles range. Its fine I guess if everything is close by.

[@repairs101]

Hi Keith. The range is about what you mentioned and is dependent on the batteries selected. Think of this build as a prototype. It used first generation Lithium-Ion Batteries from a 2015 KIA Soul which were good at the time. I’m working out all the minor kinks and inconveniences now so when the next generation Lithium-Ion Solid State batteries to be commercially available, I will just put them in. The range would most likely double. Terry.

[@KTporsche]

@@repairs101 ahh gotcha, good good ya still an achievement. Food for thought Limo could potentially get a max range since they are longer and can conceal a lot more batteries and blend the look of it. If you can make kits for that...... $$$$$$$$$$$$$$$$$

[@zeezeedex6315]

how long did this take ?

[@repairs101]

Just under 2 years from drawing board to driveway

[@Avlimusic]

Wow!!!!!!!!!!!!!

[@repairs101]

I know, right?

[@Magicinstalls]

Why would the hell would you not use a nacs plug and the supercharger from the original Tesla? You cannot fast. Charge that car now. Good luck road tripping it!

[@johndollarhide2574]

Maybe the KIA air cooled batteries/battery charge controller can't handle the current? How would you integrate it with the KIA system?

[@niacal4nia]

Very nice! Where can I convert my 1986 Porsche 928S in California? San Diego?l EV west chargers an arm & leg so an electric VW bug cost more than a new Tesla😂

[@repairs101]

You can contact Terry directly at : mooret88 at outlook dot com