83 944 LS1 Project

Hi all,

I've been lurking for a bit and it's past time that I said something about my project plans.

I have an 83 944 with 160k that I've been planning doing an LS1 conversion on eventually for years. The stock engine just doesn't cut it . Planning on three main phases to the project
- First: brakes & suspension: Wilwood's up front, 86 951 turbo calipers in rear, koni sports front and rear, 250lb weltmeister's front, 27mm rear torsion bar, 30mm front swaybar, 19mm adjustable rear, stock cookie cutters until use up current rubber on them then 17x7 17x8.5 boxster wheels
- Second: engine swap
- Third: Paint (redo original sienna red), new bumpers, other body/interior

For the engine - I have to deal with CA emissions so it'll have to be a car engine and have to pull over all the emissions equipment, etc. Of course the steering shaft vs drivers manifold/header will be an issue. Not sure if I should try to go the RH route of a further steering shaft joint to route around the manifold or try to find a CARB legal shorty header and have it modified and hope it passes scrutiny.

Still on the fence of starting with the base RH kit or not. Possibly hinges on what to do about the steering since their steering shaft mod seems to involve an attachment point on the drivers mount which is in the base kit. Either manual brakes or electric booster; manual steering already so can't see adding a steering pump just for hydroboost. Factory LSD trans that I'll keep to start; LSD still seems functional after 160k so maybe was rebuilt at some point.

I am sure someone can point you in the right direction related to steering if that is a point of concern. I remember seeing a picture of their setup and it was a series of splined U-joints that are available at Jegs.

hmmmm.....I know I've been out of circulation for a while, but what steering shaft mod?
I have an '83 and I didn't have to perform a steering shat mod.....

For Ca emissions to get around factory exhaust manifolds.

Thanks for the steering suggestion. Dug up the info from the older posts originally from xschop:

11/16" x 40 spline
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So to get around the stock exhaust manifolds, could use:
splined/DD joint -> DD shaft -> DD/DD joint -> DD shaft -> DD/splined joint

I wonder if it matters if should have both shafts out of phase or not. Has anyone switched to in phase and noticed a difference?

I assume I'll need to support one of the two sections of the steering shaft? Maybe something along the lines of:
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Look at this [You must be registered and logged in to see this link.]

Okay, the shaft support is clear enough right above the joint at the steering rack. Looks like the other end of the shaft support is a threaded rod but unclear how it's attached. Maybe that nut is welded to the motor mount? That joint at the top of the picture also looks too low to be the top joint so maybe they used 4 joints instead of just 3.

Hey Chad, once you got your Driver's side engine upright in you can then weld the large heim locknut to the upright after installing the double shaft set-up. That's the way I would do it. Im not sure of the O.D of the stock shaft but a bronze sleeve could be made to fit as a bearing...would last forever and could be changed easily.

Also I would move the heim as close as possible to the intermediate U-joint to better stabilize the set-up.

You have to mill angle to the mounting flange of the manifold. there is also part of the manifold flange that has to be ground back to clear. It's a real pain to get it to work.