Modifying/Improving the 924 Turbo

[Carrera RSR]

Update - the screamer pipe is obnoxious as soon as boost is vented. So it now has been piped back into the Hayward & Scott front section which is mated to a Dansk rear section. All now sounds business like. Wouldn't suggest its done to anything less than a highly modified 911/935/956 etc. though.

[Wes]

Some update pics of my build:-

Inlet manifold progress:-







Exhaust Mani Collector, split pulse T3:-









First Mock-up of exhaust mani:-



Exhaust Mani almost fully tack-up:-





Custom Triggerwheel for engine management:-



That gets me roughly up to date again.
All welding/fabrication is being done by my Father.

[nicksonmsport]

looking great wes, nice to see some fab work going on!

looking forward to seeing how that holset performs!

what management you going for?

really want to make some progress with mine but work is MANIC and so my project is collecting dust as i have no spare time for personal work atm! have also got a customer 944 turbo in for full reshell/rebuild.

nick

[MartinRS2K]

looking great wes, nice to see some fab work going on!

looking forward to seeing how that holset performs!

what management you going for?

really want to make some progress with mine but work is MANIC and so my project is collecting dust as i have no spare time for personal work atm! have also got a customer 944 turbo in for full reshell/rebuild.

nick

My mate has bought the 944 Turbo shell from you, really excited to see this progressing Nick

I should be coming down with him on Saturday so will meet you then

[nicksonmsport]

im looking forward to this project as well! and im really glad the shell is going to be put to proper use and will live again!

there is even a chance i have another customer lined up to buy the crashed shell from will so that may turn into another car to live again which would be great!

look forward to meeting you saturday, i take it your having the interior? its in very good shape!

nick

[MartinRS2K]

im looking forward to this project as well! and im really glad the shell is going to be put to proper use and will live again!

there is even a chance i have another customer lined up to buy the crashed shell from will so that may turn into another car to live again which would be great!

look forward to meeting you saturday, i take it your having the interior? its in very good shape!

nick

No another friend who bought Kulerzak's Silver Rose to rebuild is having the Black Sport interior and I got the interior from the SR

[Wes]

Latest pics of almost-finished twin scroll manifold. Just needs wastegate take-offs now for twin external waste gates:-

[Carrera RSR]

[Carrera RSR]

Well the engine is now just over 12 months old and has covered 12,000 miles since its rebuild last year. An emotional year!! Some highs of better than expected bhp figures followed by some lower. Coolant issues, crankcase pressure issues, some new parts here and there, a head gasket replacement which may or may not have been needed plus lots more.

So to celebrate its birthday I ditched the Piper vernier cam pulley and treated it with a more business like, GTR esque Mittelmotor version which for me is more in keeping with the engine mods.



OK this may not be a 924 'turbo' however it is a modified turbo block with a Merc supercharged placed very well on top. This car now has been MoT'd and I'm looking forward to seeing how it goes. Will certainly be well in to 200's bhp once run in and tuned to perfection. Not mine , but hopefully John comes on here soon with some more pics and info.

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[nicksonmsport]

supercharged engine looks pretty cool! be interested to see how that performs!

hoping to get my 924t progressing again soon, been MEGA busy last few months and had no time at all for my own projects.

next job is to get a fuel cell in place, close in all the rear section around the tank, cage it, fit the seats/harnesses, fit the rest of the gtr body, and finish the tubular removable front end that holds the intercooler/rad etc.

looking forward to getting stuck back in.

been in contact with mark over the last few months and his 924 gtr is immense and really making me want to get on with mine!!

soon as i make some progress will update threads

[Carrera RSR]

Not a big modifying post but some may be interested in it. I needed to adjust the light pods. I was hoping I wouldn't need to remove too many items. But one bolt was obscured by one thing, and another nut by another thing. And I ended up here.........



So whilst up in the air I did an oil change for some fresh Fuchs Titan Race Pro S 10w50.

Super large 56mm thick 944 turbo ally radiator can be seen with the 944 IC out the way. For a Chinese ebay much cheapness price of £200 including delivery in 3 days its done its job well after nearly 18 months in the car.



Also had to recalibrate the AFR/lambda sensor so took a pic of the Hayward and Scott front pipe section. This tapers out to over 3'' from the turbo before tapering back down to 2.5'' to the rear. Its a work of art although this pic doesn't show all its welds and tapering outwards and back in again. Currently run a Dansk SS rear section succesfully despite many moans of them falling apart. I must has a good one. I also have a straight through Haywood & Scott rear section without silencer. However it does nothing for the sound of my car. Far too agricultural to use. I'll get a small silencer fitted and offer it up in due course.



So got it all back together just in time as the heavens opened. Its now ready for this Saturdays Bristol Pegasus Track Day and car meet at Castle Combe. Free to rock up if anyone wants a drive out.

[Carrera RSR]

One of these kids is doing his own. one of these kids are not the same!! Also the old issue of oil pooling on the other three pistons


This is the culprit, block side of no.4 cylinder


Just wondering if holes above the exhaust valve could be causing the head to be porous and leading to the coolant pressurisation with higher boost?


Dragged out my spare head. It has at least 1mm more depth in it than this head. So they will be off for rebuilding soon.

[Carrera RSR]

Not too shabby for a van engine!!

[Carrera RSR]

New head ready to go .... awaiting the arrival of a Cometic from the USA which may be a while yet


Fresh studs and locking nuts for the manifold, the old ones looked decidedly second hand after just 18 months or severe heat cycles despite being high quality


Spark plugs protrude into the bore and potentially too close to the pistons. Need to chime in Wes here as you have a template of the piston crowns and how they interact with the head.


Previous engine builder supplied some spacers for the plugs but with this head having a touch more meat on the bone the plugs are well shrouded when using the spacers.


As discussed a few times and creates an oil/tyre/insurer debate each time - the 924 turbo badge panel v's 951 FMIC cooling debate ........ and I agree with Jon Mitchell that the 924 badge panel vents do not cut it in feeding the FMIC with enough constant cold air at any speed. So, some work in progress - decided now was a good time to fit the 951 air duct to the intercooler. This requires a large intake hole in the front bumper. So bit the bullet and got Mr Angry Grinder out and took a slice out. Its not the final shape yet. It will be squared up at each end and the corners radiused similar to the outlying shape. Should give plenty of additional cold air needed if I want to be getting more than 220bhp this year.


Other work completed - new oil separator to replace the stock Purolater. Will not improve things too much except hopefully any breathing may not spit oil from the top filter as it did with the Purolator and the filter being on the side. A new larger bore rubber pipe from block to tank as the previous one had a decent kink in it which may have inhibited some breathing. We'll see.


So now just waiting for the MLS HG and a replacement ally rad. Just need to pull my finger out and finish the wiring in of the Zeitronix data logging of the AFR/EGT/Boost/intake air temp pre and post FMIC. The Zeitronix, with Phormula knock sensor and 123ignition should make some interesting reading and protection of the engine. Just need JMG's enrichment device fitted and we should be cooking on gas!!

[Carrera RSR]

Found Wes' photo of the plugs in relation to the piston crown. Should be good to go without the spacers