Sawzall Time!!!

Well....  we're back from Amelia Island and back to the FrankenBoxster (Boxster LS:-)

There's no turning back now - there is nothing more definitive than making that first cut; and it is
the main bulkhead frame member that the motor mounts to! WOW!

I must admit it was with no small amount of trepidation that I laid the blade against the frame and pulled the trigger!  First a couple of photos and then watch the video below. The video runs about a minute and a half... then following the video are exciting welding scenes!!

                                                                   HERE'S THE BEFORE PHOTO

                                                                           
                                                                         STARTING THE CUT

                                       
                                                             
                                                              HERE'S THE "AFTER" PHOTO

                                                             
                                                       AND HERE'S WHAT CAME OUT!!!

                                           AND NOW....  FOR THE EXCITING VIDEO!

                                                     NEXT STEP - WELDING!!!!!
OK - so now we have cut out and removed a major frame member.
AND we are going to stuff 500+ HP into this thing... better put some structure back!

Very thick plate steel with two end plates welded in should bring the strength back up to snuff and better yet, it will be several inches forward of the original frame member that was removed!

WE'LL START WITH A PHOTO OF THE AREA PREPPED FOR THE PROCEDURE
 - note how large the engine cabin service access has been enlarged (you can see the seats!)

                      
                           THE PLATE BEING JIGGED AND HELD IN JUST THE RIGHT POSITION

                                                                   ONE HAPPY WELDER!

                                                       READY FOR THE SPARKS TO FLY!

                                                         AND THE SPARKS ARE FLYING!!

                    THE FINISHED PROJECT - AND THIS IS A VERY STOUT REPLACEMENT!

                                           HERE IT IS ALL CLEANED UP AND PAINTED!

SO that's it for this latest installment of the blog/posting... but keep checking as next week we'll be making lots of alterations to that brand new LS3!

Yes that's right - several changes have to be made to the brand new crate motor to fit into Boxster.
  - Oil Pan, windage tray, oil pick up tube changed out for clearance and racing baffles installed
  - Water Pump is removed and a special lower profile adapter for an electric water pump
  - Main Pulley removed and replaced with a low profile one
  - Special bracketry to relocate the alternator and the A/C compressor
  - Intake Manifold removed and flipped (ugh)
  - and there's more stuff too!

Now... if you've made it this far, here's your reward - below is a short video of us welding away.
(many thanks to my friend Dave for bringing his welder over and his welding expertise)