Boxersix's Porsche 962

The project has finally begun to take some headway here, so I decided to start a “build” thread here to display the car as well as my capabilities here. A random bunch of you here have met me and seen my work first hand, others don’t even know what I do but over the course of the next year this project will display all that and then some. Few pictures right now as 95% of this car is being built by me, right here at my shop. Chassis and suspension design are all completely mine, body is a real 962 short tail skin modified slightly by me for better aerodynamic grip at speeds in excess of 160mph.

I’ll lay out a few parameters of the car here. This is the core motor in storage now:

http://www.rspeed.org/forums/gallery/data/587/eg33core.jpg

Subaru EG33 flat six from an SVX. I am going with this motor over a Porsche engine for one reason…cost. I wanted a liquid cooled motor vs and air cooled Porsche unit and the only flat six Porsche water pumper block I’d use would be the 3.6L core used in the 996/997 Turbo/GT2/GT3. At $18K, plus Motronic DME electronics the cost far exceeded what I wanted to spend on the core motor. This EG33 will receive some one-off machine work by me at the shop. Bore and stroke increases to yield 3.45L of displacement, custom Oliver rods and JE slugs at 9.0:1 CR, stock heads with my own spec’d cam grind by WEB. Stock valve train except for updated Ferra 309 stainless intake valves and 625 inconel exhaust valves. Bumps rev limit to 7700(from 6500). Dry sump lubrication system

The system will be forced inducted via a single 3076R. The header setup is completely one off and still a bit under wraps, but I have designed it in Flow Works as an equal length long tube divided housing system. Meant specifically to produce torque right off the line, and coupled with the divided 3076R the header system should yield instant throttle response which is exactly what I’m building this car to do. Power estimates are up in the air, but Seth and I are going to shoot for a minimum of 450TQ and 400hp at 1 bar boost MAX on pump. Easy target as I’ve made well over than on my customers 911 Turbo’s with CIS and K27HF’s at 1-1.1bar boost…The proposed Hydra EMS I’ve tossed out the window due to lack of response with them and am building a one of PC3 MSII for the task. Two completey custom support systems are going to make this possible. One is a completely in house designed sequential methanol injection system. Six fuel injectors for fuel and yet an additional six injectors for the meth setup, running sequentially of their own driver based on a user defined map of RPM/BOOST/LOAD parameters and a CPS signal. Nothing out on the market works for what I want, so I’m building it :tong Second system is the one-off liquid to air intercooled charge piping that will maintain charge temps at or below ambient OAT at all times with zero heat soak. Full refrigerant cooled system that requires less physical space and weight than your typical air-air system and provides infinitely greatly cooling capacity and lower pressure drop.

The obvious stuff…Mid engine RWD, built Porsche 5 speed with cup diff and steel syncros, twin plate button QM clutch, tube chassis with integral roll cage, inboard pushrod suspension, Alcon 6 piston brakes, Fuel Safe 17gal bladder cell. I’m replicating the sequential shifter produced by Ikeya Formula(yup I found out how it works :wink: ). The suspension is full upper/lower 4130 arms, CNC’ed uprights and hubs, billet bellcranks, 4130 pushrods and links, duro-meter rose jointed pivots all around. I designed an air lift systems to work with this suspension to give me an additional 2.5" of front nose clearance at the flip of a switch. With the car slated to sit about 3" off the ground I’ll need this. Calculated weight is ~2200lbs dry

Rolling stock?..yeah it’s either going to be these sitting pretty in my storage or something completely custom from another company. Champion Motorsport forged 3 piece 18’s. Currently at 9 and 10" widths now, I may send the out to be widened to 10" and 13" F/R respectfully. Stole these when I got them, now list for ~$1300 average each if you can find a set anymore.

http://www.rspeed.org/forums/gallery/data/587/CM3piece.jpg

The goals of this project are to produce a car nobody has, and eventually put it into low number productions for clients that have always wanted such a car. Plain and simple, no crazed supercar power or ego to go after. This car with 450-500wheel be more than 99% of the public could ever handle.

I’d do have one personal goal to whoop Jesse’s WGI time and make him buy me lunch. Oh and maybe 1.15G lateral on the skid pad. It’s not going to be the fastest on the street by any means but will sure hand some asses over on the courses. I’ll post more in here as this endeavor progresses here, slowly but surely.

Sounds pretty ridiculous! Can’t wait to see progress on this thing. FWIW, I am pretty good with MegaSquirt and if you need any pointers and/or info (if you are not familiar with it) I would be glad to help out.

Nick

wow, i’m def. going to be watching this. Sounds like a sweet project. :thumb

sounds like a fun build good luck with it

962 as in the race car? Interesting motor choice and insane sounding build for sure. Best of luck.

yeah this thing should be nasty and those wheels= :thumb

To answer the inevitable next question for you, here’s a Porsche 962:

http://www.channel4.com/4car/media/features/2004/f5000/03-large/takefuji-porsche.jpg

And you’ve seen the Rothman 962 in Forza 2.

And apparently I will soon be buying a whole lot of lunches if all you have to beat with it is a 2:10-2:12.

Yes!! That was the 962 I was thinking of. Now I know this build is going to be ridiculous.

Srs bzns. [/bennyfizzle]

http://962.com/registry/956_962/962-123/DSC_1998.JPG

I didnt think those were street legal. I’ve never seen one on the street anywhere. This thing should definitly be interesting

Correct Jesse, however the short tail version instead of the more slippery and twitchy long tail beast

And if I do beat your times it’ll only be one lunch. No need to rub it in your face more than that :slight_smile: Be more fun having you sit shotgun making faces at all the 911 turbo folks we pass at PCA events while I focus on the course :nana Make some good video!

They’re typically not unless you buy a 962 and send it to Dauer to be converted for a cool 1.2M euro. There are only two real Dauers state side. This one will be different in that the entire chassis is my own, kit car registered and insured :wink: Real 962 on the outside, modernized custom stuff underneath.

Only other motor big enough in displacement and low enough of a CG to work in this car. I did have plans to CNC a center shaft to make a four rotor 26RB from a 787B, but those things have zero torque and are so high strung I’d be rebuilding it every 10K miles.

I assume you can inspect it yourself legally but you should definitly go to a liscensed inspector and see the look on his face after you register it

vry srs

I’ve got some stuff(legal too) up my sleeve I won’t disclose here just yet. It’s the ticket to making this entire project work, and beat emissions at the same time.

Wow. Hmm…so all I gotta do now is win the lotto sometime between now and when you start your limited production.

Looks tits. Can’t wait for the next update.

:wow
I want to see pics with a reg sticker and plates… That would make my day :bowdown

Gonna be a year or so yet but I’ll do you one better and bring it to a meet or two. I’m still about $30K short of finishing it.

damn that sounds like such a big price tag, any idea of when its gonna be finished?

~$40K finished parts and materials, zero labor as it’s my own designed car and built by me. Typically ~$65-70K to have a track only version built from parts commonly available, but that includes labor in the price.

Once I have the body skin, I’ll have it wrapped up in a few months. Getting the body is the task at hand right now and I have to plunk down about $7K up front for the major components and then get it here from FL. That’s gonna take awhile. I’m shooting for summer 2009.