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 Post subject: Re: My 944 S2 16 valve turbo project
PostPosted: Sat May 11, 2013 9:34 am 
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Isnt Borne the home of BRM? There must be something in the water... :drunken:

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 Post subject: Re: My 944 S2 16 valve turbo project
PostPosted: Sat May 11, 2013 9:38 am 
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I dont think that Ive heard of a 2.7l crank and 16v head combination before: most people looking at this will opt for a 3.0l crank and an 8v 2.7l head.

Im particularly interested in the liners Tim. Theyre something the frequently under-perform on these engines.

Im going to end on a helpful suggestion, although you may already have addressed the problem, but if not it may save you a fortune. You need to make a substantial brace to support the oil pickup. Cars which have run without balance shafts have frequently suffered total failures as a result of the pickup up fracturing.


Simon

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 Post subject: Re: My 944 S2 16 valve turbo project
PostPosted: Sat May 11, 2013 9:56 am 
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333pg333 wrote:
Exactly Paul, that's why I was wondering what fuel Tim was using. Can't see it being UK pump from what I understand.



Hi, We map all our engines on Shell Optimax and I'll run it on that in car


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 Post subject: Re: My 944 S2 16 valve turbo project
PostPosted: Sat May 11, 2013 10:05 am 
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944 Man wrote:
I dont think that Ive heard of a 2.7l crank and 16v head combination before: most people looking at this will opt for a 3.0l crank and an 8v 2.7l head.

Im particularly interested in the liners Tim. Theyre something the frequently under-perform on these engines.

Im going to end on a helpful suggestion, although you may already have addressed the problem, but if not it may save you a fortune. You need to make a substantial brace to support the oil pickup. Cars which have run without balance shafts have frequently suffered total failures as a result of the pickup up fracturing.


Simon


Cheers Simon. Thanks for the advice, if I take the sump off before fitting in the car I'll take a look at the pickup pipe. Should be quite easy to brace it if required. These little tips are always handy.


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 Post subject: Re: My 944 S2 16 valve turbo project
PostPosted: Sat May 11, 2013 10:07 am 
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Impressive work. So many shiny parts!

I wonder why the 16 valve head + turbo is relatively unheard of. Is there a good reason why Porsche never built one? Is the 8 valve stronger?

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Last edited by Althejazzman on Sat May 11, 2013 11:06 am, edited 1 time in total.

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 Post subject: Re: My 944 S2 16 valve turbo project
PostPosted: Sat May 11, 2013 10:21 am 
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The final incarnation of the 924 Carrera GTR used a 16v turbocharged '944' engine. A number of specialists have struggled to make FI 16v engines work though - look at the ridiculously expensive 968s which havent ever worked properly.

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 Post subject: Re: My 944 S2 16 valve turbo project
PostPosted: Sat May 11, 2013 10:37 am 
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333pg333 wrote:
Hi, I'm not a regular on this forum but it's great to read your write up and to see others around the world building up special motors for these cars. Your car looks great too. :bounce:

I would have thought you'd see higher hp figures with all that boost you're running. The stock 16v heads flow pretty well although I believe the 968 head flows even better than the S2. What fuel were you running through it? The main problem you will have with these motors is the headgasket. We have been running the Cometic h/g for a few years now on E85 and they will split around the compression ring due to cylinder head vibration. Having the 3L block will help due to the siamesed bores but you still may have these issues depending on how/where you drive it. As a pure road going car where you're only on boost for short bursts you could be ok for some time. On the track with more sustained boost is where they come apart...but the beauty of the metal h/g is you can wind down the boost and still drive home in most cases. Been there, done that.

That's a pretty large Throttle body. Be interesting to hear your impressions of this on the road as far as transient response. Have you any more pics of the turbo mounted correctly under the intake? Nice way of handling the intake without going crazy. As for reducing the torque by design. Looks to be plenty at quite early in the rpms (but at pretty high boost). ps...nobody runs these motors at such high boost even though this is not super high nowdays. A few people have run without balance shafts but not all are super happy with the outcome. Keep us in the loop how you go without yours.

As others have suggested, you will need to attend to other parts of the car to cope with the extra grunt. Suspension and brakes might need a touch up. I'd also suggest putting in a trans brace to guard against lateral movement which will bring the CVs and driveshafts undone. Sorry, phone pics aren't the best but you get the idea. Just some cheap insurance. I've also got stiffer engine/trans mounts on the track car. Look forward to reading more of your progress. Thanks for posting. :-)

ps...what are the Aussie rods you're running? Didn't know we did any down here for these cars?

Image
Image


Hi, When I started the build, I was originally looking for around 500bhp which it made rather easy. I then started pushing it, with the T04z turbo on, a little more boost and a degree or two of ignition, I think she would be well in the 700's. YB cosworth's I know like the back of my hand, the Porsche engine is new to me and all I have done is put the same design and care in to this build. I'm very pleased with the first attempt. We run it on Super unleaded.
Yes the brakes and suspension will be getting a upgrade and I will also take on board your transmission brace, looks like a sensible upgrade.
The rods or from PPM Racing, Thomas Faska , Melbourne

Cheers Tim


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 Post subject: Re: My 944 S2 16 valve turbo project
PostPosted: Sat May 11, 2013 11:22 am 
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16valve 944 Turbos are relatively rare because there is no simple bolt on manifold solution so you have to fabricate something yourself like Tim has with the S2 runners and Supra collector. Normally this is very expensive but Tim obviously has access to all the machine shop equipment he would need. Most of us just drop the 8v head from a 2.7 onto the S2 block and the standard Turbo intake and exhaust just bolt straight on.

Tim do you expect the engine to perform just as well when it is back in the car and has to cope with the normal cooling from airflow through the intercooler, radiator and oil cooler. I have no experience of how these elements are controlled on an engine Dyno but would love to know more.

How long does it take to hook the engine up to the dyno, plumb in all the piping and then connect up all the wiring to make the thing run?

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 Post subject: Re: My 944 S2 16 valve turbo project
PostPosted: Sat May 11, 2013 10:50 pm 
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Looks like a great build Tim and a good looking car too!

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 Post subject: Re: My 944 S2 16 valve turbo project
PostPosted: Sun May 12, 2013 2:52 am 
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I'd have to add that in my opinion there has been somewhat of a mystique surrounding turbocharged 16v Porsche motors. I don't think there is any great mystery. There are quite a few running fine around the world and not all of them appear on forums. Some of the builders have contributed towards this perceived situation by not being forthright with their results (or lack of them). I'm referring to U.S. builders in this case. Currently down here there are at least 2 in Sydney which are daily drivers and also enjoy success on the track. Here's Sean Buchanan in his 1986 951 which he converted to a turbo S2 motor. Driving abilities aside, you can see in a straightline that it doesn't suffer against the Current Supercar offered by Porsche in the 997 GT2RS. Sean runs E85 at approx 22psi. This car is driven daily by Sean and has not been lightened either, weighing in at 1375kgs from memory. Not bad against such a openly exalted car as the GT2RS is!
Note: Select HD format to watch these videos. http://www.youtube.com/watch?v=eM5D0DYdZgk 2nd video where the GT2RS relents. http://www.youtube.com/watch?v=QB-sE9v6ef4

I have already pointed a few 'enthusiasts' to this thread and will happily watch Tim's progress. Looks to be highly promising. :D

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 Post subject: Re: My 944 S2 16 valve turbo project
PostPosted: Sun May 12, 2013 10:50 am 
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PaulSmith wrote:
16valve 944 Turbos are relatively rare because there is no simple bolt on manifold solution so you have to fabricate something yourself like Tim has with the S2 runners and Supra collector. Normally this is very expensive but Tim obviously has access to all the machine shop equipment he would need. Most of us just drop the 8v head from a 2.7 onto the S2 block and the standard Turbo intake and exhaust just bolt straight on.

Tim do you expect the engine to perform just as well when it is back in the car and has to cope with the normal cooling from airflow through the intercooler, radiator and oil cooler. I have no experience of how these elements are controlled on an engine Dyno but would love to know more.

How long does it take to hook the engine up to the dyno, plumb in all the piping and then connect up all the wiring to make the thing run?


Hi Paul, When the engine goes back on the dyno in a couple of weeks, I am hoping to use the first turbo the Garrett Stage 5. This seemed to come on boost well and was making good power at the top end at 22 lbs of boost. I'm hoping the changes to the crossover pipe will help the back pressure problem so I can run more boost, but not much more than 1 to 1 boost/back pressure.

When back in the car, the performance loss will all depend on how good an intercooler I can get in the front and how efficient it is. Also the size of exhaust system can have an effect. The Pectel T6 ECU will keep it all in control as it looks at all the engines sensors. ie:- Charge air temp, water temp, exhaust gas temp, battery voltage etc. It then adds or subtracts fuel or ignition to keep the engine safe, and yes can alter power output.

It will take me around 3 to 4 hours to load the engine on the dyno.

Cheers Tim


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 Post subject: Re: My 944 S2 16 valve turbo project
PostPosted: Sun May 12, 2013 12:03 pm 
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Tim, what are the spec's on that Garrett turbo? Have you considered making some extractors and what size exhaust do you anticipate using?

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 Post subject: Re: My 944 S2 16 valve turbo project
PostPosted: Sun May 12, 2013 5:22 pm 
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333pg333 wrote:
Tim, what are the spec's on that Garrett turbo? Have you considered making some extractors and what size exhaust do you anticipate using?



Turbocharger - T3 Stage5 (T350) Turbine wheel with 61mm compressor wheel (61mm inducer and 82mm exducer) and .70 A/R T04S Compressor housing with 4" inlet and 2.5" outlet. .82 exhaust housing with 3" v band.
The Exhaust I am looking at coming off the turbo in 3", 3.5" if enough room and then into a twin 2.5" system.
What do you mean by extractors?


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 Post subject: Re: My 944 S2 16 valve turbo project
PostPosted: Sun May 12, 2013 5:41 pm 
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awsome to see a 944 16v engine with some real power! that will be a monster! if i had the spare cash i would love to build a widebody 944 track car with a silly engine like this!

cant wait to see videos!

nick


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 Post subject: Re: My 944 S2 16 valve turbo project
PostPosted: Sun May 12, 2013 6:04 pm 
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Tim you are a legend. Thanks for being so open & descriptive with what you're up to and why. It just goes to show that tried and tested general tuning works on a Porsche motor too.

You say you've polished and balanced the crank - why not lightening & knife edging as a matter of interest?

Are the rods you're using lighter than stock?

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