Getting there, working on the A/C system and getting the stuff under the hood to work out nicely...




























Jason

so much awesomeness.....!

Damn! Respect! LIKE is an understatement over here :thumbup:

holy smokes :wow:

keep up the good work :thumbup:

Also love you're keeping the modern creature comfort bits.

Back at it, just grinding through the details.

Fabbed up these steering column brackets, I now have a tilt AND telescoping steering wheel!!! This little bracket was a lot of work but now I can adjust the wheel for almost any seat or seating position. The nutsert tool is already paying for itself!













Finished up moving the clutch master over 1.75" as well. It's not what I would call pretty, but I'm working on my side under the dash so cut me a little slack. It is all sealed and if I ever do a renovation of this thing I can pretty it up then.










Steering column back in and we have steering again!!!







Finalized the angles, routing, and rotation of the tubes for the cooling system. I think Erik at norcalsandandoffroad got them welded up for me today. I do all the fiddley work and I let the pros do the talent stuff!







These are the details I'm most proud of, I was able to utilize the stock coolant pipe bracket even though my pathway is totally different.




Jason

More coolant work. Had to "massage" the area above the front lower control arm attachment point to allow space for the rad. Not pretty but necessary. Also welded a tunnel through two body layers for lower rad hose.




This is where the tunnel exits, then up and over the rack bellows. Tight fit.




The top and bottom hoses join next to the gas tank. Also this is a high point for the lower tubing, so a bleed bung has been added that ties into the stock Boxster coolant bleeding system. Hopefully this makes for trouble free bleeding. Very excited to be able to use the factory coolant hose bracket!




The previously dual rad system now only has one pathway. Both side bleed tubes can be seen and will be used. On a technical note, I am now aware that there are special hose clamps for silicon hoses. They have an additional internal sleeve that offers a smooth surface for the silicon to be squeezed by.







I've been able to just squeeze this monster in there, next up add the A/C condenser...




Jason

Stunning piece of work !!!

That ducting is very impressive

Respect! Nice piece of plumbing!

Small update, big progress.

I finally got the floor pan welded to the frame. It sounds simple enough, but the floor pan has a nice thick layer of German underbody sealer on it, and it all had to be ground back from the welded edge. A big mess. Then, to make it just a little more messy, I seam sealed the whole area. I forgot to get a pic, but I used a honey consistency seam sealer so I could really flow it into all the nooks and crannies. Trouble is I'm doing this upside down so I looked like I pigged out at the chocolate fountain...

Also got a jack point welded in, seen it the top part of this pic.

Anyway, here's a shot pre-sealer.




And a couple more of the rad area.







Jason

Nice Project, keep up the nice work.

En keep us posted :)

Dennis.

Big day, I finally came up with a structural solution that is also elegant in its design. It ties the inner and outer Boxster chassis, the new frame rails, and the roll cage together, all while allowing a nice edge to finish the bug/Boxster seam along.
















Also finishing up a factory-like re-attachment of all the lines running back to front.




Jason

Impressive! :thumbup:

Starting to get fun. Installed the stock Boxster trunk latch.

























Jason

Devil is in the details. There was a fatigue fracture through this area. Hope this makes it better and the decklid easier to seal against water.










Jason

Will the hood latch have a remote ?

The Boxster has a remote solenoid to pop it, then there is also a manual pull. I don't remember if my Porsche remote has anything but door locks, but I can add an aftermarket remote later that can handle the decklid latch if I want. Honestly, that little trunk is so small I don't think it will get used that often!

Jason

More body mods. Not too many things good about getting old, but a couple are patience and knowledge, so I scraped up as much of each as I could and this is what happened.

really great project you have going on here :thumbup:

Slow, tedious progress, but progress nevertheless.

Built the template for the side storage pods, the drivers side will house the rear relay block.




To close off the frame rails, I built a plug that also includes a nut to affix a bracket for the trailer hitch. I see myself building a trailer that I can haul track tires with and that is also a tent someday.










The inner fender seam between the Boxter and the bug is almost complete. Built a panel that merges the strut mount to body.













Jason

Little update:

Got these aluminum mufflers, yes, I said aluminum. Got a buddy that builds big HP cars and he swears by them, very, very light, no cracks yet for him. I'm doubtful, but they aren't that expensive and I could flange them to a stainless system if I wanted and still get big weight savings.




Ditto for cheap Chinese headers. They are supposed to be stainless, and they are except for the severely warped flange. Had to spend a bunch of time on them to get the flange flat and to open the bolt holes up. Really surprising how simple some of the mistakes are, but equally surprising how little a complete header setup was.




Working on the fitment to the fenders, these will have to be widened ever so slightly unless I like the smell of burnt rubber around every corner. Looks kinda cool though...













Finally got the condenser attached to the rad, used aluminum spacers my wife uses for her business, re-threaded them for metric, and had Eric at NorCal Motorsportz weld them on for me.













A before shot of the area I need to fill between the Boxster chassis and the tubing.







The mess I have yet to tackle...




Jason

Still going strong :)

Very impressive!

I'm very suprised that the wheelbase is almost the same, reffering to one of your first shots with the beetle body hanging over the porsche.

OMFG...what a cool project!

Great project!

waiting for an update on this awesome project,

The details continue - gauge cluster now.

Cut the stock speedo ring and moved it over 1.5". It was really tricky because I couldn't put the cluster in level, didn't flow with the curves, and it couldn't flow with the curve because it would look too tilted, I ended up with a compromise between the two.



















Jason

Front and rear latches will be controlled by stock solenoids. Deepest part of front latch aluminum will be embedded in fiberglass to bond it to inner hood surface.

Love the cluster!

MAN! That is awesome..! Keep u the work. Amazing..! :thumbup: :thumbup:

How's the progress on this awesome project?

Stopped at least for another month, bought a new house and need to build a new shop, I'll post again when momentum returns!

Jason

Great project!!

Looking forward to see some more pictures.

:thumbup:

Any updates yet? Pics of the new shop are welcome too :)

Dirt is still being moved on our hillside, should have a flat spot to build a 26'x40' shop next week. 0 progress on this project, of course things take more time than you expect to get rolling.

Here's a shot of a Super/Boxster S from Sweden, hope to be doing this in my bug next year.

https://vimeo.com/m/99021642

Jason

Updates !

Nothing new to report, she just sitting there. A roller, yes, but no progress. May be done with engineering next week on the garage structure, but don't expect to be working on it again for at least a couple of months.

Jason

I read on germanlook your pics are dead because of hosting them on Facebook.
Did you know you can host them on here too!