Pelican Parts Porsche Boxster Big Bore Kit: The Ultimate Guide to Upgrading Your Engine

If you own a Porsche Boxster and crave more power, a big bore kit is one of the most effective upgrades. This guide focuses specifically on big bore kits available through Pelican Parts, a trusted supplier of Porsche components. We'll walk you through what a big bore kit does, what options exist, and what to consider before buying. Whether you have a 986 or 987 Boxster, this article will help you make an informed decision.

Understanding Big Bore Kits for the Porsche Boxster

What a Big Bore Kit Does

A big bore kit increases the engine's displacement by enlarging the cylinder bore. For the Boxster's flat-six engine, this typically involves replacing the original cylinders with larger ones and fitting oversized pistons. The result is more torque and horsepower across the rev range. Typical gains range from 20 to 40 hp depending on the kit and supporting modifications.

Benefits and Considerations

• Power Increase: More displacement means more air and fuel burned per cycle, delivering noticeable acceleration and top-end pull.
• Reliability: Quality kits use upgraded materials like Nikasil-coated cylinders and forged pistons, which can actually improve durability under high loads.
• Installation Complexity: This is a major engine-out job. It requires disassembling the engine, machining the crankcase, and precise assembly. Not a weekend project.
• Cost: Parts alone can run $3,000–$6,000, plus labor if you pay a shop. Budget accordingly.

The Pelican Parts Advantage for Boxster Upgrades

Pelican Parts is a go-to vendor for Porsche enthusiasts. Their inventory includes big bore kits from top manufacturers, and they provide detailed product descriptions and technical support.

Quality and Selection

Pelican Parts carries kits from LN Engineering, Flat6 Innovations, and other reputable brands. They stock common sizes like 3.6L (for 2.7L engines) and 3.8L (for 3.2L engines). Each kit includes pistons, cylinders, rings, and often gaskets. You can trust that the parts match original specs or exceed them.

Customer Support and Technical Resources

Their website features installation guides, forum discussions, and a dedicated tech line. Before buying, you can call to verify compatibility with your specific Boxster model year. This reduces the risk of ordering the wrong parts.

Comparing Big Bore Kits Available at Pelican Parts

LN Engineering Big Bore Kits

LN Engineering is a leading manufacturer known for high-quality cylinder coatings and precision machining. Their Boxster kits are offered in 3.6L and 3.8L displacements. The 3.6L kit works with the original 2.7L engine, while the 3.8L suits the 3.2L. Pros: Excellent materials, proven performance, and they include new wrist pins and circlips. Cons: Higher price point, and you may need to buy head gaskets separately.

Flat6 Innovations Big Bore Kits

Flat6 Innovations offers a slightly more budget-friendly option, also available in 3.6L and 3.8L. Their pistons are forged from 2618 aluminum for strength. Kits come with complete gasket sets and piston rings. Some owners report slightly less peak power than LN kits but still a solid upgrade. Both brands require machining of the crankcase to accept larger cylinders.

Sizing Considerations

• 3.6L Upgrade: Ideal for Boxster S (3.2L) owners wanting a modest bump. Gains around 25 hp. Keeps the engine tractable.
• 3.8L Upgrade: Best for 2.7L base models or those seeking maximum displacement. Gains up to 40 hp. But it needs higher octane fuel and a proper tune.

Required Supporting Mods

A big bore kit is not a standalone upgrade. To realize the full potential, you'll need:

• ECU Tune: Custom mapping for air/fuel ratios and timing. Pelican Parts sells the Duramaxtune or offers mail-in tuning.
• Exhaust System: Less restrictive headers and mufflers help the engine breathe. Consider a full cat-back system.
• Cooling Upgrades: More power produces more heat. Upgraded oil coolers or a larger radiator may be wise for track use.
• Clutch: Stock clutch may slip with increased torque. Look at performance clutches like those from Sachs.

Installation Considerations and Cost

DIY vs Professional Install

If you have extensive engine-building experience, you can tackle this at home. You'll need specialized tools like a cylinder honing plate, torque wrenches, and engine hoist. The factory service manual is essential. Expect it to take 20–30 hours.

Most owners prefer a professional shop. A Porsche specialist will have done many such jobs. Labor costs range from $2,000 to $4,000 depending on location and shop rates. Add another $500–$1,000 for machine work (crankcase boring, decking).

Estimated Total Cost

• Parts (big bore kit): $3,000–$6,000
• Supporting mods (tune, exhaust, clutch): $2,000–$4,000
• Labor and machine work: $2,500–$5,000
• Total: $7,500–$15,000

This is a significant investment, but it transforms the car into a more thrilling machine.

Final Recommendation: Which Boxster Big Bore Kit from Pelican Parts Is Right for You?

Choose based on your goals and budget:

• For daily driving with occasional spirited runs: The 3.6L LN Engineering kit paired with a basic tune is a reliable choice. It gives a noticeable kick without making the car fussy.
• For track or autocross use: Go with the 3.8L Flat6 Innovations kit, plus a full exhaust and race-oriented tune. The extra power will shave seconds off lap times.
• If budget is tight: Start with a used kit or buy a complete engine already built. Pelican Parts sometimes stocks short blocks.

Always call Pelican Parts before ordering to confirm fitment for your specific year and model. They can also recommend a local installer. With the right setup, your Boxster will feel like a Porsche 911 in disguise—but with that glorious mid-engine balance intact.

Remember, a big bore kit is a serious engine modification. Plan your entire build, including fueling and cooling, to ensure longevity. Enjoy the extra power responsibly.