Series 1 Turbo with 944 intercooler

[CarreraRSR]

As you may know I'm in the process of fitting a 944 turbo front end with front mounted intercooler to my Series 1 turbo

Just a few questions

1. Expected bhp increase based on fact rather than internet myths and hearsay (some say 20bhp, some say 40bhp!)
2. Although it will be dyno'd to optimise ignition and fuelling, what is required to be done to both after fitment? Can it run satisfactory until the dyno or not. Boost will be left alone in the near future. If air is colder, therefore denser then I guess mixture should be adjusted?
3. Is lag going to be more noticeable with longer air travel? More switch like on boost v's off?

Any other points?

Please fact rather than hearsay

 

[924nutter]

This was done way back, professionally with a watercooled i/c and the engine made 196 so its either 19 or 26 depending on which engine they started out with. Good luck with the lag with that length of inlet tract and the pint sized turbo on the 924. The 944 might use a k26 as well but its not the same internals and they lag quite a lot. I am going with a bell intercooler exactly where it is on the CGT but with a three inch core which after making a dummy out of craft cardboard will just squeeze under the bonnet.

I will reply to the mixture question at another time as the long text wont load and I am not going to type it all back in again tonight

 

[924nutter]

As promised. The amount of fuel metered to the back of the inlet valve, (cis is continuous and fuel pools behind the inlet valve while it is closed) is proprtional to the mass of air passing through the metering head. As matter cannot be created or destroyed only changed in state, the mass of air passing into the cylinders will be the same as that which passes through the metering head. The difference is that because of boyles law the air will be denser i.e molecules more tightly compacted, but the same mass of air will have metered the right amount of fuel for any given mass, so except at maximumm airflow I would expect the mixture to be very close to correct. The advantage is gained by the higher pressure achieved after igntion, All imho and subject to correction by more knowledgable people. We know that the metering head runs out of capacity somewhere between 210 and 245 bhp because the CGTs has to have the metering head from an eight cylinder Mercedes, with siamesed outlets feeding one injector.

 

[CarreraRSR]

Certainly be happy with circa 20bhp increase and the weight saving I've done.

The last dyno showed 158bhp at the wheels so 20bhp on that with circa 1100kgs should make it fun.

 

[CarreraRSR]

Well the 944 front end is in, new bolt on badge panel lines up with the new bonnet. Just the wings to replace and its getting a full body paint strip to bare metal. Into paint for the end of the month.

 

[944 man]

Im presuming that youve used a series two 944 bumper cross member? Is it possible, do you think, to relieve the panels on a 924S, in order to fit a 951 intercooler? I dont think that I will have room to fit a replica 937 intercooler, as Im not using an original engine.

Simon

 

[CarreraRSR]

Some metal work and fabrication needed but certainly possible. Here's a 924 S I found on t'interweb

 

[944 man]

Extremely useful, thank you.

Simon

 

[CarreraRSR]

No problem.

If you decide to use a 931 badge panel on a 924S or 944 front end you will need to push out the section between the headlights and intercooler as can be seen in the outside vent aperture below

Here with both sides push out and rewelded

 

[MGBV8]

Just trying to get my head around the 931 badge panel swap.
Nic keeps hinting that she's seriously thinking about doing that to her car so we're just trying to work out exactly what is involved.

I believe her badge panel is spot welded on, being an '83 model 944?
Is it simply a case of drilling out all the old spot welds and then modifying the flange for the rad support as per the last photo?

Are there enough brackets and flanges already on the car to enable a bolt on fitment to a car previously fitted with a welded panel, or is there any further fabrication work needed?

 

[CarreraRSR]

The turbo vented badge panel and your early 944 panel have approx 40 spot welds both on the bonnet shut area and underneath where it buts to the front bumper. A spot weld drill bit will have them out but can distort the panel when removing so be careful. I would weld up all the spot weld holes on the panel and the nose area of the car, grind back, prime and paint. The new panel can be drilled and screwed to fit and become removable. Some self tapping screws and speed fasteners will have it back on and off in a jiffy. The slam panel does not need to be swapped out.

The nose section I have came complete from a late 944 S2/turbo shell. These cars already have a removable badge panel. I also found through a year of searching and trying to buy a bolt on turbo badge panel. They are quite rare and command some £££'s. The main reason for the S2/turbo nose was primarily for mounting an intercooler not for the bolt on badge panel, but for me kills two birds with one stone.

 

[pixie*porsche]

Thank you for the info.

Would it not be a stronger fit to puddle weld the new badge panel onto the shell, using the holes made by drilling out the spot welds? I'm struggling to see why I would have to remove the panel on a n/a 944?

 

[CarreraRSR]

You don't have to remove it. But you or the next owner might. If you spent the time removing the panel why not make it bolt on and future proof it?? 6 and two 3's! No strength is required on this panel for the integrity of the shell.

 

[MGBV8]

Good stuff. I take it that the front bumper and valance need to be removed to gain access to all the spot welds?

 

[CarreraRSR]

Yes, around 20 to 30 underneath the panel. Another 10+ on the slam panel above. Theres also a screw each side going into the wings. Pop up the lights, remove a rubber scraper and its tucked up in the corners.

 

[pixie*porsche]

Thank you for your help []

I'll have to save this page for when I get hold of a panel.

Jon saw one on eBay yesterday and was going to tell me when I got home, it was gone before I got back though...[]