PSH
PCGB Member
Good day all
Well I've been threatening to do this for a while so about time I got started, I will give advance warning here that this build will not be a quick build, as well as the car I'm also in the middle of major house renovation and garden landscaping, plus my main hobby of live steam model engineering , they all take up valuable time which when you get to my age ( 52) you start to realise that you just don't have enough years left to do all that you wish, so although I'm stating my planned route of build here things may and probably will change along the way. First, a little history of the car spec to date, I think most here know now that on a good day my car had a power output of 368 bhp and 382 lb torque at the flywheel, rear wheel figure was 326 bhp. She did as some here will know loose some power in more recent times which stumped me for a while but eventually I found the cause which was due mainly to my lack of understanding on valve movement/hydraulic tappets and nothing to do with the car or it's components, I won't be making the same mistake again..
The car is a 1986 model that I've owned for over 14 years and like most started off with light mods that progressively grew.
First mod (1998) was a Lindsey boost Enhancer, not a real power gain but it felt quicker
Next (2000) was a Lindsey dual port wastegate with manual boost controller, this was then mapped on a dyno by Wayne Scofield, resulting power 282bhp/282torque.
Followed by (2005) 368bhp/382torque
So what do you need to make a reliable 368 bhp
Block remained standard, it's an 86 car that means forged internals and crank designed for over 500bhp, later cars used the same crank but not forged components.
Lindsey Stage 2 Head with ceramic exhaust coating and machined valves for greater flow, all ports polished and map flowed.
Cometic head gasket
Lindsey Super 61 Turbo
Siemens 55lb injectors
Lindsey Dual Port wastegate
New standard Hydraulic Tappets
Manual boost controller
NGK Iridium Plugs
Magnecor 8.5mm Red Leads
150mm K&N cone filter
Vitesse MAF with piggyback system
Intercooler: standard
Bailey Motorsport DV30 re-circulating valve
Exhaust: standard
silicone vac lines
Innovate Air Fuel Ratio meter/gauge
Adjustable fuel regulator
8 Hours mapping on a dyno at Chip Wizards Rochdale by the maestro himself Wayne Scofield. Car was set to run on 95 RON ( for safety) at 17psi. For those not in the know for every extra RON grade used you can safely increase the boost by 2 psi, so if I had requested the car set for 98 RON the boost could have been increased to 23psi and be just as safe, or so the theory goes ,of course the power would have been a lot higher, back then I was a little scared of going to far, so played safe, today I'm far more confident in the engines capabilities although I still do not intend to use all of the boost available.
Note: If I've forgotten anything I'll add it later
Now before I get started on the new build some things were added to the old spec but never put on a dyno to remap.
Janspeed twin rear exhaust section
Piper Ram intake system, custom install
Apex-i AVC-R electronic boost controller
Engine loom fully rewired using Lindsey components and covered in 1200 degree sheaving.
All sensors renewed
Dump to atmosphere Cosworth type dump valve
Stepper motor boost gauge with record
89' Turbo gearbox with LSD
I think that's covered most of it, I haven't gone into brakes and suspension , I think this intro is long enough I don't want to bore you guy's on the first page now do I... I will add though that as far as bodywork is concerned the car remains standard.
Ok, so plans for this build, first stage, items marked with star already acquired
Block: bored/skimmed out to 101mm *
Con-rods to remain unchanged although will be checked for balance, whilst researching the options the general consensus is that you can't beat the original Porsche forged items as used for the Turbo cup cars. As a point of interest I've read that the 83 N/A 944 has the same rods, strange.*
Pistons: IASA 101mm full race spec forged pistons with extra machined grove below the first ring, this allows a far higher boost without risk of blow by past the rings.*
IASA gudgeon pins*
Crankshaft machined undersize 0.25mm , both main and rod journals*
Raceware Head stud kit*
Raceware Main stud kit*
Raceware rod stud kit*
Genuine Porsche 0.25mm oversize Main/rod bearings*
Crankshaft scraper*
replace, oil pump/water pump/belts/tensioners/pulley's
Lindsey lightweight billet flywheel
Lindsey stage 2 clutch, 6 paddle
Speed Force Racing Stage 2 large intercooler
Speed Force racing oil cooler
Lindsey stage 2 head, rework valves to F1 spec hemisphere profile
Lindsey Turbo super 61 rebuilt
Vitesse + V-flex MAF for ignition timing
3" custom made Magnaflow free-flow exhaust including the all important turbo downpipe*
Of course a lot of what is already on the car will be reused after a good clean or rebuild where needed
last but not least the all important remap, by Wayne of course
edit: add Vitesse wasted spark to list
Planned second stage:
Stand alone EMS, not decided on which yet although inclined towards the TEC3-R EMS but need a little more research before commiting
Speed Force Racing stage 2 headers including cross over pipe, 3" turbo downpipe, 3" test pipe and 3" back box.
Ok I think that covers what's planned and what came before , as stated this will be a long process but I intend to be very heavy with pictures to help others both with building modified 944's but also as a picture reference of the 944 engine's workings that may make things easier for others in regards to general servicing on the 944.
I was going to post a few pictures of empty engine bay and partly stripped block but seem to be having an issue with photobucket just now but will try again later today, for now at least details of intent have been given which took me some time as is was.
Feel free to make any comments or suggestions good or bad, this thread is mostly aimed at helping others like mined to myself and hopefully help them avoid possible future mistakes.
Needless to say... more to come..
Pete
Well I've been threatening to do this for a while so about time I got started, I will give advance warning here that this build will not be a quick build, as well as the car I'm also in the middle of major house renovation and garden landscaping, plus my main hobby of live steam model engineering , they all take up valuable time which when you get to my age ( 52) you start to realise that you just don't have enough years left to do all that you wish, so although I'm stating my planned route of build here things may and probably will change along the way. First, a little history of the car spec to date, I think most here know now that on a good day my car had a power output of 368 bhp and 382 lb torque at the flywheel, rear wheel figure was 326 bhp. She did as some here will know loose some power in more recent times which stumped me for a while but eventually I found the cause which was due mainly to my lack of understanding on valve movement/hydraulic tappets and nothing to do with the car or it's components, I won't be making the same mistake again..
The car is a 1986 model that I've owned for over 14 years and like most started off with light mods that progressively grew.
First mod (1998) was a Lindsey boost Enhancer, not a real power gain but it felt quicker
Next (2000) was a Lindsey dual port wastegate with manual boost controller, this was then mapped on a dyno by Wayne Scofield, resulting power 282bhp/282torque.
Followed by (2005) 368bhp/382torque
So what do you need to make a reliable 368 bhp
Block remained standard, it's an 86 car that means forged internals and crank designed for over 500bhp, later cars used the same crank but not forged components.
Lindsey Stage 2 Head with ceramic exhaust coating and machined valves for greater flow, all ports polished and map flowed.
Cometic head gasket
Lindsey Super 61 Turbo
Siemens 55lb injectors
Lindsey Dual Port wastegate
New standard Hydraulic Tappets
Manual boost controller
NGK Iridium Plugs
Magnecor 8.5mm Red Leads
150mm K&N cone filter
Vitesse MAF with piggyback system
Intercooler: standard
Bailey Motorsport DV30 re-circulating valve
Exhaust: standard
silicone vac lines
Innovate Air Fuel Ratio meter/gauge
Adjustable fuel regulator
8 Hours mapping on a dyno at Chip Wizards Rochdale by the maestro himself Wayne Scofield. Car was set to run on 95 RON ( for safety) at 17psi. For those not in the know for every extra RON grade used you can safely increase the boost by 2 psi, so if I had requested the car set for 98 RON the boost could have been increased to 23psi and be just as safe, or so the theory goes ,of course the power would have been a lot higher, back then I was a little scared of going to far, so played safe, today I'm far more confident in the engines capabilities although I still do not intend to use all of the boost available.
Note: If I've forgotten anything I'll add it later
Now before I get started on the new build some things were added to the old spec but never put on a dyno to remap.
Janspeed twin rear exhaust section
Piper Ram intake system, custom install
Apex-i AVC-R electronic boost controller
Engine loom fully rewired using Lindsey components and covered in 1200 degree sheaving.
All sensors renewed
Dump to atmosphere Cosworth type dump valve
Stepper motor boost gauge with record
89' Turbo gearbox with LSD
I think that's covered most of it, I haven't gone into brakes and suspension , I think this intro is long enough I don't want to bore you guy's on the first page now do I...
I will add though that as far as bodywork is concerned the car remains standard.Ok, so plans for this build, first stage, items marked with star already acquired
Block: bored/skimmed out to 101mm *
Con-rods to remain unchanged although will be checked for balance, whilst researching the options the general consensus is that you can't beat the original Porsche forged items as used for the Turbo cup cars. As a point of interest I've read that the 83 N/A 944 has the same rods, strange.*
Pistons: IASA 101mm full race spec forged pistons with extra machined grove below the first ring, this allows a far higher boost without risk of blow by past the rings.*
IASA gudgeon pins*
Crankshaft machined undersize 0.25mm , both main and rod journals*
Raceware Head stud kit*
Raceware Main stud kit*
Raceware rod stud kit*
Genuine Porsche 0.25mm oversize Main/rod bearings*
Crankshaft scraper*
replace, oil pump/water pump/belts/tensioners/pulley's
Lindsey lightweight billet flywheel
Lindsey stage 2 clutch, 6 paddle
Speed Force Racing Stage 2 large intercooler
Speed Force racing oil cooler
Lindsey stage 2 head, rework valves to F1 spec hemisphere profile
Lindsey Turbo super 61 rebuilt
Vitesse + V-flex MAF for ignition timing
3" custom made Magnaflow free-flow exhaust including the all important turbo downpipe*
Of course a lot of what is already on the car will be reused after a good clean or rebuild where needed
last but not least the all important remap, by Wayne of course
edit: add Vitesse wasted spark to list
Planned second stage:
Stand alone EMS, not decided on which yet although inclined towards the TEC3-R EMS but need a little more research before commiting
Speed Force Racing stage 2 headers including cross over pipe, 3" turbo downpipe, 3" test pipe and 3" back box.
Ok I think that covers what's planned and what came before , as stated this will be a long process but I intend to be very heavy with pictures to help others both with building modified 944's but also as a picture reference of the 944 engine's workings that may make things easier for others in regards to general servicing on the 944.
I was going to post a few pictures of empty engine bay and partly stripped block but seem to be having an issue with photobucket just now but will try again later today, for now at least details of intent have been given which took me some time as is was.
Feel free to make any comments or suggestions good or bad, this thread is mostly aimed at helping others like mined to myself and hopefully help them avoid possible future mistakes.
Needless to say... more to come..
Pete
