The Porsche 944 turbo EFR 7064 project

[R/E 951]

Update 4 Its been a while since I last updated so thought I'd let you all know how I've been getting on. Alot of the time since I last updates has been spent designing and waiting for parts to be machined. One of the parts Ive had made for the car is the turbo adapter. This makes the transition from the original turbo mount to the oil drain on the EFR 7064. It is a two part adapter made from stainless and Ali. All the structural strength in the adapter is in the stainless.

I also had a boss made up for the original water temperature switch in the turbo water line. This is also made from stainless.

I have also had the hanger brackets for the exhaust laser cut and they have turned out very nicely.

While waiting for these parts to be made I got some heat wrap for my headers and also put in some ports for testing back pressure. These are in headers 1 and 3.

So once I had the parts gathered up I got stuck into my exhaust. The complete system is back purged and surprisingly light weight I haven't weighed it yet but I'd say lighter than OEM.

I am now doing the finishing touches to my x-over before welding it up. This will be completed this week. Once this is done I have an AOS can to make and a couple of heat shields and I can start to make noise. I intend to do some experimenting with the mapping on this car to see what improvements are in it for turbo response. I intend to try lean spool and also some mild anti-lag type mapping in the higher rev range to keep the turbo spinning during gear changes, the ECU fuel cut will protect the turbo and exhaust from getting too hot.

 

[Frenchy]

Keep it coming, interesting !

 

[R/E 951]

Update 5 I have finally reached the stage where parts are going on for the last time. Here is a few pictures of the replacement AOS can that will give the DP more room as well as not having problems with standing heat.

This took a great deal of time to get right but looks the business now. I intend to get it Zircotec coated when I do some other bits on the car. I have also finished my X-over and am pleased with how it has turned out. I have heat wrapped it along with the rest of the under bonnet exhaust components.

This is a general under bonnet image from a few days ago, things are starting to take shape.

I have all the metal work etc complete now so I've taken everything off and am cleaning as I reinstall for the last time. This should mean the car will be running very soon and I can't wait!!!

 

[TTM]

Nice work! Interesting to see how you will route exhaust tubes out of the wastegates.

 

[Diver944]

Really love the fabrication of the much needed custom parts to make this turbocharger fit. Keep up the good work, when do you think it will be finished?

 

[944 man]

ORIGINAL: TTM Nice work! Interesting to see how you will route exhaust tubes out of the wastegates.

Yes indeed. Are they planned to re-enter the exhaust or will they end up scaring pedestrians? []

 

[R/E 951]

Update 6 Thanks for the encouraging comments its taken a fair amount of time and some serious work but I think its definitely worth the effort. So the car has been started since my last update and all is well. There are a few minor things to be done which is to be expected with so many changes but they wont take long. When the car is running and all back together I'll get a video for you all to have a listen, I personally think the twin-scroll gives the car a different sound and its not the exhaust as my dads 951 has pretty much the identical 3" exhaust and they don't sound the same. Here is a few pictures of the car now. This is the turbo bolted in for the last time.

These are the wastegates and cross-over in place. I will be interested to see how they perform. I've seen many similar setups on other cars which worked fine and I don't see why they shouldn't but time will tell. Currently they are dumping under the car for testing and to make it easy to change wastegate springs and the like. However they can be quite easily piped to the centre tunnel and ultimately I'd like them exiting behind the drivers door.

I have also received my new AOS cap You will notice it sits quite low, this is due to the current intake manifold being spaced out from the head to give more room for the turbo. The top of the engine will be very much unfinished until I get my intake manifold and new intercooler made.

This the engine bay from the top.

Hope this is of interest and if your looking forward to the results then you can imagine how I feel :bounce:

 

[R/E 951]

ORIGINAL: 944 man

ORIGINAL: TTM Nice work! Interesting to see how you will route exhaust tubes out of the wastegates.

Yes indeed. Are they planned to re-enter the exhaust or will they end up scaring pedestrians? []

They will probably end up scaring pedestrians however for those who are interested I didn't think it would be a problem to pipe them into the exhaust.

 

[R/E 951]

ORIGINAL: Diver944 Really love the fabrication of the much needed custom parts to make this turbocharger fit. Keep up the good work, when do you think it will be finished?

Should be finished in the next week or two. This includes a good road tune.

 

[T3rra]

Be great to get some date logs for comparison to mine. Quality looks great

 

[TTM]

The wastegates are a tight fit... Hope your engine mounts are in good order otherwise they might be touching here or there? Looking forward to a video []

 

[R/E 951]

Update 7 Just a quick update to let you hear the car running in the garage. This is without any tuning done what so ever. If all goes well I'll have the car out of the garage tomorrow and it'll be getting a road tune. Youtube link: http://youtu.be/P7tIwBe8Lhk

 

[TTM]

Sounds really "clean", if that makes sense. Looking forward to your first driving impressions.

 

[333pg333]

Yes, it does sounds somehow different. Well so it should, being the first 944 with an EFR turbo that I know of. Congratulations on the fine work.

 

[R/E 951]

Update 8 So the car was out today and took it up the road for a spin. First impressions are that the turbo is a lot more responsive than expected. This duel scroll stuff really works! The other surprise it the turbo makes a far bit of noise. I expect its the fact the BOV it integrated into the compressor housing but when dumping air it does sound somewhat like the Mclaren P1 Not a bad complaint! So at the moment my wastegate springs are 0.5 bar which don't seem to be opening at all which indicates my back pressure is low. This means I was limited in tests but this the information I have. Looking back through my logs my boost threshold is as follows: 0.2 bar = 2124 RPM 0.3 bar = 2191 RPM 0.4 bar = 2305 RPM 0.5 bar = 2416 RPM 0.8 bar = 2750 RPM 1 bar = 2880 RPM 1.2 bar = 3017 RPM Also as regards response if I step on it at 3150 RPM I see 1 BAR at 3350 RPM this is approximately 1 sec Another example is started at 3400 RPM and 1 BAR is seen at 3550 RPM This is all with a very poor tune with AFR's between 10.5 and 11.5 with is far to rich. Im going to aim for 13 below 3000rpm. This is to raise EGT's and to help spool up while not over shooting 13.3 which is lean best torque. Considering the EFR 7064 has a big turbine as well as the fact it has a 1.05 A/R housing it goes to show with a combination of the Gamma-Ti turbine and the dual scroll housing seems to produce the results. This should also mean the car is very free revving which I'm looking forward to. Its safe to say I'm very pleased and looking forward to driving the car for the next 6 months. I will update you with a video and the final results from this turbo soon may even get to a dyno.

 

[R/E 951]

ORIGINAL: TTM Sounds really "clean", if that makes sense. Looking forward to your first driving impressions.

I think I no what you mean. This car has always been very smooth but once the Augtronic was put on things got even better. After spending this afternoon using toms software I cant stress enough what a great and simple set-up it is. I would put it miles ahead of any set-up Ive read about due to its simplicity, high speed processor, great software and the very wide base of features and upgrades available. Then theres the great after service, tom never fails to answer quires and has a wealth of experience with electronics which is very valuable.

 

[R/E 951]

ORIGINAL: 333pg333 Yes, it does sounds somehow different. Well so it should, being the first 944 with an EFR turbo that I know of. Congratulations on the fine work.

Thanks, Its been great getting the positive comments along the way as theres been alot of work done in the last couple of months and I'm very pleased/ relieved its been successful. I can tell you the turbo sounds even more special when working!

 

[TTM]

You see 1 bar of boost at 2800 rpm and you still want to improve spool... [] With such a an early boost build up I am tempted to think you will see an unreasonable level of back pressure at higher rpm. You most likely won't be able to reach the low level of EGT needed to make a difference in spool, but advancing ign timing should make a much bigger difference. With an AFR of ~13 you are likely to cause knock because of the restrictive standard camshaft and intake manifold combination that does not like too much timing. Just speculation though, and looking forward to further results. Congrats for the great work!

 

[TTM]

Hello, Any progress on this interesting project?

 

[J.C944TurboMan]

Amazing , over the years I have seen somes mods on the 944 Turbos , But my hat goes off to you !! This is Evolution Will you not get naked flames coming out of the two beautiful waste gates ?? Please post a link of the sound of the engine once up and running !! Great work