The Porsche 944 turbo EFR 7064 project

[R/E 951]

ORIGINAL: TTM Hello, Any progress on this interesting project?

TTM, Update 9 I've been very busy the last while and haven't made as much progress as I'd have liked but I've managed to get a few days off in the coming week and intend to get out and make some headway. The plan is to get the car running on some 80lb injectors I've put in as I didn't want to run high fuel pressure after inspecting some of the fuel pipes under the car. I then want to get to the dyno (dyno dynamics) and get a base line for my project, from that I can analyse upgrades like wasted spark and eventually I'd like to run sequential injection and ignition. Some of the time I've spent doing different interior changes. I have fitted a pair of Recaro pole position seats which I am very pleased with, At the same time I put in a 968 CS rear seat delete which I'd had waiting in the garage for a while.

I also plan to cover my under dash and centre console in red leather as well as make some nice 964 carrera RS style door cards incorporating some 968 CS manual window winders. I also intend to fit a turbo s non sunroof roof skin and then get a red alcantara roof cloth like the 997 GT2 RS. This should make a nice unique interior. I have also done some work on my gear linkage and lever. I fitted a only 944 rear linkage which took most of the slack out but I still wasn't happy so I got two 10mm SKF roller bearings and made a housing and pin for them and then welded the housing to the old linkage bar that runs to the gearbox. At the same time I also extended my gear stick up to leave it much closer to the steering wheel. The linkage now has zero slack and is really nice to use. Its also in the perfect position when driving with a noticeable difference to before.

One of the parts I have been working at while I haven't had time to get to the workshop is the design of my new intake manifold. It is now pretty much complete and I will start to get some of the parts made soon. It will be a new manifold from the ground up not using any part of the old manifold or fuel rail. I will have a dual carbon plenum to keep weight down and provide an even flow across cylinders. It will have individual Jenvey throttle bodies and short runners. While designing the intake I pulled out an old 951 head of dads which had been in the corner of the garage for a long time. While take dimensions off it for my manifold I also noticed it has a 48mm intake valve and a ported intake to, he has kindly said I can use it on my car. I will have a few modifications to enable me to run 2 fuel injectors per cylinder but has the bulk of the work that I was intending to have done to my head done already. I am now on the look out for a good block with good bores that I can put a deck plate in and keep my original engine original. This is just a small update as to what I've been doing and I'll update in the next week or so with how I get on with some more tuning.

 

[TTM]

Thanks for the update, quite interested to hear/see more about the intake manifold when possible.

 

[333pg333]

Very nice progress! It's going to be something really special when you've finished. Not that it isn't now. [] Sounds like your Dad had been hording a 2.7L head. The port shape should be different. Also interested on the intake. Keep up the great work!

 

[George Elliott]

Hmmmm, I bought that head from a Forum member years ago, he had moved on to a 3.2 litre and later to own WUF. Then I - being short of time, moved on to my current daily driver with an SPS BB turbo and the Head sat gathering dust, before being discovered recently. George 944t

 

[333pg333]

Hang on George...is this like the scene in Starwars where Darth 'comes out' as Luke's father...[]

 

[TTM]

Haha Patrick, also what I just realised. Good family values here! []

 

[R/E 951]

Just a few images of a delivery that arrived today.

I'm very pleased with these, they aren't cheap but certainly are the business when you see them in the flesh. I will update you some more as the intake manifold project develops.

 

[R/E 951]

Update I thought I'd give you a small update on whats been happening regarding my car. I now have the waste gate controlling boost properly however they aren't pulling full boost yet due to only having a 0.3bar spring which with just spring pressure is pulling 0.5bar to 0.4bar across the rev range so back pressure is very low at this point. The car pulls very well considering how low the boost is and the open waste gate's aren't as horrific as I expected. I won't be changing the springs as I only want the lightest springs I can when I get my ECU controlled boost control working which should be in the next couple of weeks. I will get a video when I have the car running full boost so you can hear and see how great it is. I have also been speccing the engine which I will build over the course of the summer and fit next winter along with some chassis upgrades. The engine will be 2.5 litre with standard bore and stroke but thats where "standard" ends, the rods will be 156mm Carrillo's from a Mitsubishi which results in a much shorter compression height and there for lighter pistons, it also results in a better rod to stroke ratio and therefore a smaller rod angle which means less load on the skirt of the piston, this enables me to go for a semi skirt piston which also reduces weight. The new rod also has a 22mm pin (24mm standard) which will also reduce weight but not strength. The pistons will be custom JE running 8.5CR. I also will be running as little piston to head clearance as I can to get the best out of the 8V quench area. This should help provide an efficient burn. The pistons will be running in Darton MID sleeves which will mean I have a very strong base for a big torque motor. I think I'll get over 400ft/lbs at 4000RPM and torque peaking at 5000rpm. I have also been making some progress on my intake. After much time drawing ideas, chopping and changing it was time to get some test pieces made up. This was just to get our bearings as to what it looks like on the head and I will fit it onto my car to see how much room we make for the turbo, I say "we" as my dad deserves all the credit for this "test" plenum which we will be able to change key dimensions quickly and easily on a dyno to see what produces the best compromise for this turbo and engine package. We will also be adding and removing runner length to move the torque around and see the results.

As you can see there there is a slight spark plug issue which will have to be fixed but all in all I think it looks rather well. You will also notice the injectors are different, there will be two fuel injectors on this car one small very effecient for super smooth idle and great economy probably running in sequential mode and also the big 80lb injector I'm currently running with for bulk fuel delivery under boost. I hope to also run a set of direct port water injectors which are the shorter row farther up the runner. the target water delivery will be 12% of fuel delivered.

These will be going on next winter with other structural improvements. A few images of engine bits.

Big valve head

Ported intake ports

Hope this is of interest. Will update more on the turbo progress and also manifold in due course.

 

[Diver944]

Still loving this project [8D] Why do projects always have to take so long [&o] I get so impatient to see the finish

 

[nick_968]

Indeed Paul - why do they take so long.....can't quite seem to finish mine either!

 

[R/E 951]

Update I have never got round to doing any videos of my car and the turbo response, this is partly as I've been occupied at other more interesting/ important things and also due to the fact videoing this car on the road with its current level of performance may not be wise. So I am going to postpone that idea until I get to a track or dyno.

However I have been doing a few things that may be interesting. I have been expanding the capabilities of Augtronic on my car and am now running throttle and RPM based boost control which are working very well and I find makes the car much nicer to try and control.

I also have installed a turbo speed sensor which I am also logging through the ECU which means I am now able to put a fairly accurate number on how much power the car is producing based on the air going through the turbo.

Here is an EFR matchbot that is based upon data from logs. EFR Matchbot 7064

This log shows the throttle based boost control in operation as I struggle to get traction in 1st.



This log shows a 2nd, 3rd and some of 4th gear. As can be seen from the acceleration values the car pulls very consistently to 6800rpm. In this log the AFR's are a bit rich, I now have it running between 11 - 11.5 AFR. Interestingly it feels quite a bit quicker with AFRs around 11. The external ADC is the turbo speed and is a fraction of 5v, it tops out at 6400rpm and is doing 112,000rpm at that point. On the response the turbo only looses around 30,000rpm during a gear change and from throttle open to 2200mbars absolute is 300ms which interestingly is around the time it takes for a humans eye to blink []

At this stage I think the engine is at the limit of it internals. I only have two things I'd like to do to the current engine which are to try a few things to smooth out the boost curve a bit and also I am in the process of upgrading to a better ignition system to improve engine efficiency.

I will update the progress on my new engine in due course.

Regards, Rob