Planet 9

Well the install of the TPC Turbo kit is finally on it's way. Cheerio's shop has been tied up, so finally got it cleared out last night and we took the time to unbox and put everything on a work bench, plus set out all the tools we need so the install will be a much smoother process. We should have the car on the lift today, and well have more pics and info to share as we progress on the install. So check back soon!

Nice Hara. How long does a install like this take? Keep us Posted, I'd love to hear about the results.

Please take lots of pics.. I am following you lead :-)

We will do our install in 2 weeks.....

__________________
eXperimental Vehicle = TPC turbo - car wide LED lighting - Magden computer - Traqmate - DNX9140 and more - all self installed. ( with the Great help of many on this board! )

On a DIY scale of 1 to 10, 10 being most difficult, this rates an...


ARE YOU FREAKING INSANE??????

...on my scale.

Please do your best to document the process for the timid.

__________________
2007 Speed Yellow Cayman GT 2.7 (retired)
2008 Guards Red Cayman GT 3.4 (retired)
2012 Carrara White Cayman R
"Carpe Cayman"

Please keep us up to date.

If you can photograph the process, I'd really be happy - and grateful1

mike

Ok here's a little update from today. Thanks again to Cheerio for the help with the shop, also MoWilson329 for coming out for the support and help! We started in the afternoon and only got about 4hrs into the install but I think we got a lot done. Everything went pretty smooth so far, hope it keeps going that way

Ok on to some pics from today. Here's Cheerio and MoWilson329 arriving at the shop.



One bad thing with having a car that's slammed is getting it on the lift lol.. We had to drive the car on to wood blocks be able to swing the lift arms under the car.





Once the car was on the lift we disconnected the battery:



Bumper is off so we can get access to the 3rd radiator which will now be used to cool the water/air cooler:



Next all the under panels has to be removed to be able to snake the new coolant pipes to the 3rd radiator:



Out with the Tubi.. My lucky brother wil be getting this I am going to miss the sound from it though



Once the exhaust is out of the way we removed the brackets holding the exhaust in place:



We also had to loosen the lower beam to be able to remove the under panel:



Rear under tray slides out after removing the 6 bolts holding it in place, we will need to modify this later on to attach the water and oil pump supplied with the kit:



Next we move on to removing the intake box, which I was told is pretty much the most difficult part of the install:

The OEM needs to be removed, so once all 4 clamps are loosened and the throttle body detached from the intake hose, the whole unit will just slide out:





Next the MAF and intake hose is removed by loosening the 2 hose clamps:



Next will need to remove the left side fuel rail and intake manifold to be able to get the intake box out:



Manifold is out of the way, but the intake box still cannot be removed yet...



I know this is going to look rough, taking a saw like that on a car :-p but it went rather smooth. The intake box will need to be modified to fit the new setup, so we opted to cut the box and remove it in pieces:



Here's what we have with the box and manifold removed:



So that's it pretty much for today, it was dinner time so we decided to call it quits. Will continue tomorrow...

Here's a final image I wanted to share.. Cheerio, insisted on being neat and making sure every bolt was put into bags so we can identify where everything, when we bolt everything back up. So in the end if we have 1 bolt left over we failed

Thanks for the awesome sharing... Best wishes for a smooth wrapout.

Yeah, today was great.

I was pleasantly surprised that we didn't hit any major hangups. I hope it will go just as well for the rest of the project.

I will add to Harajuka's commentary by saying that some suggest dropping the front of the engine to get more room to "disassemble" the stock air box for removal. But we found with enough people to hold the box, and a steady hand, you can remove the air box without dropping the engine.

And a lift is almost a requirement for this kind of project. It just makes a lot of steps way easier.

I should be able to modify the stock airbox during the day tomorrow and prepare for another work session tomorrow night.

This is getting really exciting.

Great sharing. Thanks & best of luck for everything to go smoothly.

BTW, while I appreciate this being documented as it happens in the forum, please take the time at the end to transfer it all to the Articles section in an article or article series for storage and ease of future access. Best of luck with the install!

PS. Don't forget the Turboencabulator!

__________________

My Garage | My Gallery | My Articles | My Blog |My Classifieds
K-Man S

Very cool! Definately on my list of "when the warranty expires" items! Do you Jacksonville guys ever meet up? I do alot of contract work in Brunswick and would love to check out some of your mods.

thomashpsn,

We do get together quite a bit. There is a Cars and Coffee meet on the second Saturday of every month that most of us attend. Then there are other times when we get together just for various other reasons (lunch, mods, pictures, etc).

If you head down this way just shoot us an email and we will meet up with you. We have met several other members from here too.

__________________
Cliff

2011 Boxster Spyder
2007 Cayman S- GONE, but not forgotten!
2007 Base Cayman

More More?


So the reason to take apart the top of the engine, was just for the Airfilter / box change?


Where are the injectors located?

Regards

D

__________________
eXperimental Vehicle = TPC turbo - car wide LED lighting - Magden computer - Traqmate - DNX9140 and more - all self installed. ( with the Great help of many on this board! )

I Should have more pics later, left the camera at the shop. But last night we got a bit done not much, we finished modding the air box, mounted the new oil pump and got the new spark plugs installed which was a pain..

The reason the top manifold was removed is to get to the airbox and also to attach other oil returns etc. I will know more once I get to that point of the install.

Injectors are located right on the side of the intake manifold, which can be replace without removing the manifold.

Ok here is some progress from yesterday, doesn't look like much since its just moding the air box, and installing new spark plugs and mounting the oil pump.

So with the air box out of the car, we need to trim down the intake box to move the MAF sensor to the the inside of the box.. we started by cutting down the sides.



We use a large 3 1/2" drill to drill a big enough hole to fit the maf sensor.



Here's how it looks with the maf inside the box.



Completed box



Next we moved on to mounting the oil pump that will pump the oil from the turbo back into the engine.



Here's the new pump mounted on the bottom tray



Last thing we did for the night is unbolt the ecu which will be sent to TPC Racing to get it flashed.



More to come..

Why was such a big change of the air box needed?

__________________
eXperimental Vehicle = TPC turbo - car wide LED lighting - Magden computer - Traqmate - DNX9140 and more - all self installed. ( with the Great help of many on this board! )

The MAF has to be moved into the intake box, since the new intake pipes will need to be routed differently.

HAHA, I think you should put a rocket on that airbox and send it into space, kind of looks like a small satellite.

So did TPC supply the that gold lining as well?

Getting exciting!

__________________
eXperimental Vehicle = TPC turbo - car wide LED lighting - Magden computer - Traqmate - DNX9140 and more - all self installed. ( with the Great help of many on this board! )

this is exciting stuff as i am hoping to following you down this route in the very near future

Theres bound to be a good reason for this but as i can't see th area concerned in the flesh i can't help wondering why the airbox isn't deleted all together and the new cone airfilter routed near to intake directly?
on the subject of the grill/air intake, does TPC recommend removing the baffle plate in the grill (a la desnorkle) to get a strong airflow into the engine or is their advice to leave well alone?

keep up the good work, wish i was states side to see an install in the flesh before ordering mine.
a pssenger ride in one would also have been great before buying.
never mind it just adds to my desire to emigrate from the rainy/damp/cloudy UK to somewhere sunny!
I must be mad owning a Boxster S with our climate!


Thanks

Mark