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ralphmusic
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2015/07/08 08:15:35 (permalink)

Upgrading a 981 PDK Cayman

In late 2013 I swapped a 997 Carrera GTS for 981 Cayman S with PDK and have enjoyed the easier handling and greater agility of the Cayman, however the 3.4L engine it is a bit weak on power.
 
A few months after my purchase, rumours about the GT4 started so I placed my letter of intent in March 2014 with a friendly salesman from whom I had previously purchased cars and referred prospects to. But around September/October 2014 it was looking likely that the GT4 would be manual only and with a dodgy left knee and a recent left shoulder operation, even a left hand drive manual GT4 did not seem a good idea. I therefore started looking at other alternatives for getting more power in a PDK equipped Cayman.
 
It rapidly became evident that without a custom ECU tune the benefits of any engine modifications would be substantially reduced by the new generation OEM ECU which only a very few can tune. There are a number of USA firms who have installed 3.8L engines in 986 and 987 non-DFI generation Boxster/Cayman models, but first, together with a fellow PCGB member I explored using RuF. Unfortunately they wanted around €65k +VAT for just the engine swap with new exhaust system and related front/rear PUs, so that did not make much sense. 
 
So over to the USA where BGB Motorsports in Florida are the most active and have been providing 3.8L road conversions and building and running manual and PDK 3.8L race cars. After extensive discussions with BGB primarily focussing on support and logistics (at that time they had only converted USA-based owners’ cars), their then lack of a true custom ECU tune and the prospects of shipping engines back and forth killed that alternative.
 
Interestingly the USA is the only territory where Porsche will give a trade-in credit for a 3.4L or 2.7L against a new or re-man 3.8L.. Therefore if I wanted to do the swap, I had to get a 3.8L engine which at £20k from Porsche UK was a tad expensive… so off to fleabay and lo and behold in December a 3.8L became available from a 3,700 mile PDK 991S involved in a front-end crash.
 
But in December there was still some, but not a lot of hope that the GT4 would have a PDK option. I took a deep breath and after Fearnsport had checked the 3.8L fleabay engine I bought it, thinking that if a PDK GT4 became available, I’d sell the 3.8L engine and any loss would be the option cost of having both the PDK GT4 and 3.8L upgrade choices.
 
In parallel, a German group led by Jens Ehresmann contacted me via planet9 and we started discussions about having them install the 3.8L engine in my Cayman. Jens had been modifying his PDK 981 Boxster S 3.4L and with intake and exhaust modifications plus custom tune had achieved around 370PS. He had also upgraded the brakes with 996 GT3 parts and fiitted 997 GT3 Cup suspension acquired from race teams that his group supports. Not content with this, Jens then acquired a 991 3.8L Powerkit engine and fitted this to his Boxster - the key to getting 370PS from a 3.4L and 434PS from the 3.8L Powerkit was his ability to custom tune the ECU, particularly for the Powerkit engine’s multi-valved plenum. Ehresmann have recently started providing custom tune ECUs to BGB, modified a 987 Cayman R to give 371PS for a Norwegian customer, and have introduced a tuning package for the GT4.
 
Early February, GT4 orders opened and I had to turn down the option to buy one as it was indeed manual only. With that alternative closed, I finalised arrangements with Jens’ group. I left my Cayman at Fearnsport late February to join the 3.8L engine and arranged for both to transported to Jens in Dusseldorf whilst we headed off on our Spring break. The conversion would normally take three weeks or less but as we were going to be away for some time and mine was their first Cayman swap, it seemed sensible to give them plenty of slack in the timetable.
 
I collected the car just in time to join April's Spring PCGB Factory Tour which took in Osnabruck, Leipzig and Stuttgart. This gave me plenty of time to get comfortable with the ‘new’ car and its reliability before leaving Germany. Back in the UK on my journey from Chunnel to Devon, I stopped off at Goodwood for a noise test (at 101db it was OK) and ran it on a dyno, which confirmed Jens' power runs.
 
The installation is not that “difficult” The picture below shows the 3.4L and 3.8L (or is it 3.8L and 3.4L?) engines together and they have the same overall external dimensions.
 

 
There are some differences including siting of the oil filter and some pipe runs but they all fit in the engine bay. In the 981 the gearbox is aft of the engine versus being in front of the engine in the 991 so the 3.8L engine orientation is reversed. The 981 gearbox is retained and mates directly onto the 991 engine. As Jens’ Boxster and BGB’s conversions demonstrate, there is no problem in installing a Powerkit 3.8L in either a Boxster or Cayman.
 
So what have I got?
 
3.8L 991S engine with Cargraphics 200 cell headers, IPD plenum + Y tube, and BMC air filter
Custom Tune with 412PS and 419Nm on a Maha dyno
Center radiator
991S 6 piston callipers/340mm disks
K&N anti roll bars and Powerflex Camber/Castor front bushes
Cargraphics 8.5" and 11.0” 20” wheels with Michelin Pilot Super Sport Tyres F245/35 R295/30
 

The power is greater than 3.8L engines in 991S and GT4 mainly due to the custom tune, better intake, and 200 cell headers/manifolds. The BMC v OEM air filter gave another 7 PS which is symptomatic of how breathless these engines are at top-end with the standard intakes.
 
It is not intended to be a homebrew GT4 nor a Cayman version of the lightweight 981 Boxster Spyder. I like my comforts (which is why it weighs 1428kg) and is a very much better road car with so much more usable torque. The power does not fall away at the top end and it runs to OEM rev limits with no CELs. I get 34mpg on m/way runs and it will hold 7th gear up inclines. It has very much stronger mid-range accelaration and is much less frenetic on track than in 3.4L guise. Aside from the Cargraphics wheels, the car looks completely standard.
 
I have not done much yet on the suspension, just stiffer anti-roll bars, extra camber adjustment and wider tyres. The car does need development in this area so I am off to Centre Gravity to have the car ‘audited’ and define and discuss options. I plan on running the car though the autumn as is and will implement over winter whatever best option emerges. 
 
I considered fitting the TechArt aero kit because according to SportAuto, the Cayman S develops front end lift and rear downforce. However TechArt were unable to provide any data on its aero effect and as I did not take off at speed on the autobahn the €5.5k cost did not seem a good investment. 
 
Warranty? - I would be miffed if a door handle fell off and Porsche would not fix it but I have gone well beyond different make windscreen wipers/battery/non N rated tyres. 
 
Insurance? checked this early - it is rated as a Carrera S and all mods have been disclosed - another £75pa.
 
DVLA? changed V5C to show new engine serial# and capacity.

 
You have to be brave to do something like this but with research and cross checking to validate claims and experiences, one can manage the risks and it is a car I shall keep for a little while.
post edited by ralphmusic - 2015/07/08 08:17:36

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Motorhead
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Re: Upgrading a 981 PDK Cayman 2015/07/08 11:04:29 (permalink)
Ralph, thanks for posting. I'd heard from another member that you'd taken the plunge - a very brave decision on your part bearing in mind warranty and potential selling-on issues - and am very pleased that you've now chosen to share your experiences here with us. It sounds as though the transformation was worthwhile and has made the car a more focused track weapon while not spoiling the on-road experience.
 
Interesting to note that the 991S engine plus performance upgrades fitted into the Cayman engine bay without difficulty. I wonder why Preuninger reckoned that modifications were required during GT4 development? Have you kept your original engine or sold it on?
 
How much additional camber adjustment do the Powerflex bushes provide? Have you left the rear brakes standard?
 
Keep us posted on progress and good luck with the venture.
 
Jeff

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CLIFFWILKINS
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Re: Upgrading a 981 PDK Cayman 2015/07/08 12:30:48 (permalink)
Hi Ralph 
All sounds great especially those  who can't have a GT4.
Are Fern Motorsport doing this custom tune kit for 987 CRs if so can you shed any light on what this consists of and a rough cost.
Cheers Cliff.

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ralphmusic
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Re: Upgrading a 981 PDK Cayman 2015/07/08 13:36:20 (permalink)
Cliff,
Fearnsport just conducted a pre-purchase inspection of the engine and stored it for me before I had it and the car shipped to Germany. 
 
Jens Ehresmann did the conversion and he is based in Dusseldorf. He has recently completed a 987.2 Cayman R power upgrade for a Norwegian client. You can see details at http://www.pistonheads.com/gassing/topic.asp?h=0&f=231&t=1496254&mid=321031&i=700&nmt=Cayman+R+%2D+owners%2Fbuyers%2Fmods+&mid=321031 posted by Axel987  also page 34.
 
Jens is on Facebook at    https://www.facebook.com/pages/Ehresmann-Automotive-GmbH/325484277652791  he tells me he is working on a version in English but it is currently only in German.
 
I found Jens very straightforward to deal with and I suggest you contact him directly as he is a better source than I to provide costings.
 
Ralph

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ralphmusic
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Re: Upgrading a 981 PDK Cayman 2015/07/08 13:45:27 (permalink)
Motorhead
...Interesting to note that the 991S engine plus performance upgrades fitted into the Cayman engine bay without difficulty. I wonder why Preuninger reckoned that modifications were required during GT4 development?

Jeff as the GT4 has a different rear suspension it may be that this presented different challenges
Motorhead
Have you kept your original engine or sold it on?

It will be sold in Germany to a race team
Motorhead
How much additional camber adjustment do the Powerflex bushes provide? Have you left the rear brakes standard?

Powerflex effect is less than claimed so far (having another geo soon) and rears are standard but will probably go for 325mm Girodisk upgrade when disks need replacing - I currently get through rear pads quickly but the disks seem to taking a while to wear out.

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andywill
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Re: Upgrading a 981 PDK Cayman 2015/07/08 14:09:43 (permalink)
Very interesting project,
Motorhead
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Re: Upgrading a 981 PDK Cayman 2015/07/08 16:06:54 (permalink)
ralphmusic
Motorhead
...Interesting to note that the 991S engine plus performance upgrades fitted into the Cayman engine bay without difficulty. I wonder why Preuninger reckoned that modifications were required during GT4 development?

Jeff as the GT4 has a different rear suspension it may be that this presented different challenges
Motorhead
Have you kept your original engine or sold it on?

It will be sold in Germany to a race team
Motorhead
How much additional camber adjustment do the Powerflex bushes provide? Have you left the rear brakes standard?

Powerflex effect is less than claimed so far (having another geo soon) and rears are standard but will probably go for 325mm Girodisk upgrade when disks need replacing - I currently get through rear pads quickly but the disks seem to taking a while to wear out.




Thanks Ralph. Yes, it could be that the GT4's modified rear cross-member encroaches on the space for the engine.
 
I assumed that the Powerflex bushes were just a straight replacement for the standard items. If they can they be oriented to change the camber I would have thought that the effect would be minimal, but I'm sure that CG will be able to sort you out.
 
Jeff

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carreraboy
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Re: Upgrading a 981 PDK Cayman. 2015/07/08 18:19:48 (permalink)
Always good to hear from the more modern cars and how they too are adaptable as the older cars all be it more technical.
 
Excellent Post Ralph …. a real GT4 Buster
 
Keep us posted on any further developments and running report please.

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Re: Upgrading a 981 PDK Cayman. 2015/07/08 21:27:06 (permalink)
No wonder you told me earlier tonight that your car also makes an odd ticking noise, I'm not surprised!
steve WS 
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Re: Upgrading a 981 PDK Cayman. 2015/07/09 12:35:01 (permalink)
love it,  must be crazy fast, >400bhp and PDK in a Cayman
 
what's not to like,
 
Awesome ;-)
 
I want a go in it ;-)

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Re: Upgrading a 981 PDK Cayman. 2015/07/09 14:50:57 (permalink)
Interesting series of mods to make a great track and road car, it must be a treat to have the greater torque and power of the 3.8 on tap whenever you feel the need, did you consider turbo or supercharging of the 3.4? Just curious as there have been some conversions available and wondered what your investigations had turned up such as possible negatives to that route.
 
By comparison I've had a 944 turbo which kicked the power in as soon as the turbo spooled up and I've had a 968 Tiptronic which I tended to drive in manual mode no turbo but 16 valves and the 8V turbo was more fun to drive performance was similar on both but such differences in character.

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Motorhead
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Re: Upgrading a 981 PDK Cayman. 2015/07/09 17:09:38 (permalink)
Kevan,
 
A pity Ralph can't extract even more power from the 3.8L engine using TPC Racing's Turbo Kit:
 
http://www.tpcracing.com/tpc-997-996-turbo-kit.html
 
Unfortunately, it's only suitable for 996/997-series cars.
 
Jeff
 
 

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ralphmusic
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Re: Upgrading a 981 PDK Cayman. 2015/07/09 17:26:02 (permalink)
Buddy
...did you consider turbo or supercharging of the 3.4? Just curious as there have been some conversions available and wondered what your investigations had turned up such as possible negatives to that route.....



Buddy, some previous upgrades by others and some alternatives....
 
1. On the wild side for earlier versions is a 4.2L engine build   http://www.914world.com/bbs2/index.php?showtopic=176298
 
2. Farnbacher Loles Cayman  http://www.amarisupercars.com/detail?vid=39656  where is it now? Loles (supplier of the engine) had an interesting life http://www.newstimes.com/news/article/Millionaire-scam-artist-faces-30-years-5264070.php
 
3. 981 Turbo kit, will TPC ever finalise it??  http://www.planet-9.com/tpc-turbo-kits/96957-teaser-981-cayman-s-turbo.html  first post after initial build and road and dyno testing was in May 2014 - still nothing. Parr are TPC distributors and have converted at least one 987 (think non-DFI) Cayman and I have seen a Boxster somewhere but don't recall the generation or origin of the kit
 
4. Fitting IPD plenum, larger throttle body, larger exhaust etc to a 981 without ECU tune will not yield much improvement - see
http://www.planet-9.com/981-cayman-boxster-modifications/90815-ipd-981-boxster-s-plenum-install-dyno-results-comparisons.html
 
I went the 3.8L route because there was a continuous history going back to at least 2006 of these being done in the USA, there were reports by happy owners of no problems and going back for further modifications. Also in the USA they have been racing 3.4L, 3.8L, manual and PDK Caymans in various series, and a number of people reported track day use in extreme temperature and elevation. Also the 3.8L is being used without an extra level of stress that turbo or supercharging might bring without good torque management.
 
The key for DFI normally aspirated engines is the ECU tune. The OEM maps close the throttle from about 85% max to 55% from around 4k revs thus limiting intake volumes. Turbo conversions and indeed TPC's 355 Atmo kit (referred to in 4 above) use a piggy back arrangement to fool the ECU but this is far from a custom tune.
 
Nobody is doing much on 981s in the UK so if you want to get something done about power, and whilst I may sound like a Ehresmann fan-boy they are, so far as I have found the only group around capable of custom tuning the 991/981 ECUs. They can also take the DFI 3.4L (987.2 and 981) up to 370PS with intake / exhaust mods and tune but that is probably the limit without internal modifications to the engine.
 
And having just seen Jeff's post about turbo charging a 3.8L, if I ever wanted to get more power I would have the Powerkit fitted but actually the torque is not much more (and is not so strong low down) and is 'only' 22PS more. It does have a different character though with a strong top end as I recall from my 997 GTS.
 
Ralph
post edited by ralphmusic - 2015/07/09 17:30:45

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ralphmusic
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Re: Upgrading a 981 PDK Cayman. 2015/07/09 20:41:05 (permalink)

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Re: Upgrading a 981 PDK Cayman. 2015/07/10 12:01:46 (permalink)
Sounds like a very expensive way to create a GT4 look-alike Ralph.
 
On the subject of Cayman turbocharging, as you say TPC Racing in the US have been providing turbo kits for a number of years and I've a feeling that Parr Motorsport used the TPC kit for their car [ http://www.evo.co.uk/porsche/cayman-s/6776/parr-porsche-cayman-s-turbo ], with some additions.
 
SVP in Droitwich have also got into the act and have also been developing both 3.7-litre and 3.9-litre engine conversions [ http://www.specialistvehiclepreparations.com/blog/ ]. They've even developed a supercharged car for a champion hillclimb driver which includes a Sadev sequential transmission.
 
These turbo conversions appear to be aimed at 987 rather than 981 customers, but we won't have to wait long now for Porsche to show us what they've developed.
 
Jeff

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ralphmusic
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Re: Upgrading a 981 PDK Cayman. 2015/07/10 13:45:47 (permalink)
Motorhead
Sounds like a very expensive way to create a GT4 look-alike Ralph.

 
..and if you believe SportAuto's supertest the GT4 aero effect is pretty small. The real benefit of the GT4 over my road car is in the chassis and brakes.
 
MotorheadSVP in Droitwich have also got into the act and have also been developing both 3.7-litre and 3.9-litre engine conversions [ http://www.specialistvehiclepreparations.com/blog/ ]. They've even developed a supercharged car for a champion hillclimb driver which includes a Sadev sequential transmission.

 
i am visiting SVP in a week or so but my first contact was not particularly inspiring and they have no particular experience of 981 - if I were running a similar business I too would concentrate on the larger market of 986/987 non-DFI cars.
 

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Re: Upgrading a 981 PDK Cayman. 2015/07/11 07:22:18 (permalink)
My visit to Centre Gravity disclosed some toe and camber inconsistencies across and between axles which explained why the car was tending to drift left with neutral power and right under power (last geo was by a well known indy that fitted the Powerflex bushes). Chris did not have time to remedy and was unable to schedule any work until August so yesterday Exeter OPC adjusted the suspension for me. Their initial readings matched Chris' (always a useful confidence point) and we set it up with -2':00" camber/zero toe front and at the rear, max OEM camber-1':45" and OEM 0':10 toe. Hopefully this will now provide a base platform for understanding what further suspension parts might usefully be changed over the winter to improve.

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Re: Upgrading a 981 PDK Cayman. 2015/07/11 10:47:30 (permalink)
Ralph,
 
Any idea how much extra camber change the Powerflex TCA inner bushes provide for the front suspension? I suppose the next step would be to upgrade to adjustable length TCAs like those used on the GT3/4 which I presume will fit without modifying the front hubs, although I seem to recall that the GT4 uses the 991 Turbo hubs. I assume that the 991S 6-pot brake calipers and discs didn't require any hub modifications.
 
It's a pity there isn't much scope for rear suspension camber adjustability.
 
Jeff

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Re: Upgrading a 981 PDK Cayman. 2015/07/11 12:16:17 (permalink)
Motorhead
Ralph,
 
Any idea how much extra camber change the Powerflex TCA inner bushes provide for the front suspension? I suppose the next step would be to upgrade to adjustable length TCAs like those used on the GT3/4 which I presume will fit without modifying the front hubs, although I seem to recall that the GT4 uses the 991 Turbo hubs. I assume that the 991S 6-pot brake calipers and discs didn't require any hub modifications.
 
It's a pity there isn't much scope for rear suspension camber adjustability.
 
Jeff



Jeff,
 
On the basis that we got to -1:05 before the bushes were fitted, I guess the answer is 1 degree.
 
What next is the question I shall answer by the winter. Look at Elephant Racing to see how to adjust most things and spend a fortune. I think one given will be to replace the dampers with some that will better suit road and track and allow corner weighting and ride height to be set. There are several candidates with a range of capabilities and costs. Benefits v cost needs to be understood as always.
 
Responding to the brakes question and speaking generally, fitting non-GT 991 parts on 981 models does not seem to present engineering challenges.
 
 
Ralph

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Re: Upgrading a 981 PDK Cayman. 2015/07/11 16:05:00 (permalink)
camberinconsistenciesacross    Is this the longest word in the English dictionary 

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