3,2 turbo conversion kit or plans

[greyes59]

Hi there,

I have a stock 3,2 engine which I would like to turbocharge.
I am looking for advice or plans on how to go about it.

Thanks,
George

[Tippy]

Todd Knighton of Protomotive used to make a kit that retrofitted your existing EFI to accommodate boost.

Or, some have chosen the route of using a rising rate fuel pressure regulator from BEGI to increase fuel pressure during boost and an MSD boost timing master (BTM) to retard timing. The BTM can retard 0-3 degrees per pound of boost.

On the turbo side, you can purchase any 930 headers out there. Rarely8 is a member who makes really nice ones. I'd opt for a T4 flange one as a 3.2 flows much more air than a 930 which uses a T3 flange.

Intercoolers can either be super cheap if you are a DIY type, or crazy expensive to have custom fabbed. eBay has a plethora of IC's you can adapt for next to nothing. CXRacing makes very inexpensive ones. I prefer vertical flow as they have the least amount of pressure drop and outflow (CFM wise) the same dimensioned horizontal flow. Less pressure loss equals less pressure in the turbine housing resulting in more hp (reduced backpressure).

Silicone couplers too can come from eBay for cheap. I prefer the European hose clamps that are smooth so they do not bite into the silicone. They also look nicer and more OEM IMO.

Wastegates - TiAL makes the F46, which is a direct replacement for "elephant trunk" headers of the 930. I would get TiAL or TurboSmart. Do not skimp on the wastegate. Your motor depends on it!!!

Blow off valve - again, TiAL and TurboSmart make nice ones. eBay sells some TurboSmart ripoffs that work fine. It's up to your moral compass if you would purchase one or not.

I am a huge fan of the S300 series Borg-Warners. Any model from the S360 (60mm) up to the S369 (69mm) would be fine for a 3.2 IMO. I'd stick with the S360 if you want to stay low boost. Go bigger if you plan on upping the hp in the future and boost levels.

Buy the biggest K&N you can find, cone type, and adapt to fit inside the engine compartment. I made a 4" inlet pipe fit the 3.2. Had to 'oval' the pipe, but got it to fit.

[Raceboy]

Why mess with RRFPR or other hacks when one can just plug in a standalone ECU and have it working properly with correctly sized injectors etc? WBO2 is needed in any case so total cost difference is minimal..

[Uncle]

What Raceboy said. There is more black arts in getting hacks to work than there is fitting a decent ECU.

I'd chuck the standard injectors in the bin and fit some new ones upto the task along with a fuel system update. New pumps filters etc.

As Tippy said intercooler is the easy bit along with the gate.

I wouldn't bother with a BOV. I've got a draw full of them. Turbos have moved on.

[baloo]

Originally Posted by Uncle

...
I wouldn't bother with a BOV. I've got a draw full of them. Turbos have moved on.

Uncle,
Would you elaborate on eliminating the BOV?
When, why was it determined after all these decades that it really was not necessary.
Yep, I'd like to eliminate as much paraphernalia as possible.
Thanks.

[Uncle]

Most modern turbos don’t have an issue with compressor surge. Metallurgy tech has advanced since the 3LDZ and things like shafts are no longer made out of things that go snap if you look at them the wrong way.
I’ve got a GT42R turbo on a 1UZ Toyota V8 in a Tacoma that’s has been on there making damn near 600RWHP for a 5 years. No BOV no issue. Street car/Drag car.
My old Silver 930 has a BW366 on it with EFI,3.2 mani etc with a conservative low stress 423RWHP. No BOV no issue. Street car.
My old Blue/Matte Black 3.0ltr with EFI 3.0ltr TD25G turbo. 350RWHP. No BOV no issue. Steer car.
My little shop partners 758RWHP JZA70. 8 years no BOV no issue. Not a drag car sees regular hill climbs on off throttle applications.
Current 934rep. EFI,964 heads, GT3 crank 3.4ltr bla bla bla 450something RWHP. No BOV no issue. Circuit car/Hill Climb car.

I could go on but you get the point. The key is a decent intake set up without crappy clamps and the minimum amount of silicon. Roll the edges of all the pipework or if you can’t do that a decent bead of weld, use Wiggins clamps and have everything mounted correctly. Simply set it up correctly. The JZA70 has been running close to 30psi for 8yrs and never blown a pipe off nor hurt the turbo. The Tacoma close to 25psi and is the same deal. Never blown a pipe off or hurt the turbo.

[Tippy]

Didn’t know you had a S366 on your 930? What boost are you at?

BOV’s aid boost recovery if I’m not mistaken between shifts. I could be wrong.

[Uncle]

I sold the silver thing with the 366 on it a couple of years back. Off the top of my head it was around 1 bar. The feel of the car was classic old school 930 whack in the back of the head with a 2” x 4” power delivery.
Current car is the same boost but a GT35r. It makes more power but it comes on earlier and over a larger rev range. I’m kinda kicking myself as I recently sold a Sierra Cosworth with the a great little EFR turbo that would have been perfect for a twin set up.
In an old bush turbo yeah I would agree that a BOV will aid in boost recovery. BB turbo not so much.
I think you will struggle to find say a WRC car with a BOV. Granted they consider the turbo as somewhat of a consumable but there is more at play than simply comp surge. There is also the small matter of dumping in raw fuel for anti lag that’s taking its toll on the turbo.
You’ll struggle to find anyone that manufactures or sells BOV’s saying you don’t need one though for some reason. Don’t get me wrong I’m not at all saying you shouldn’t have one. I am just saying you don’t need to have one either.

[cmcfaul]

Whats the expected HP gain on a 3.2 with .5 bar of boost?

More specifically I have an 89 G50 Carrera 3.2 with SW chip, cat bypass and maxflow muffler. Shes a heavy beast so looking for more, bolt on power.

Have an opportunity to buy an almost complete turbo setup. Big intercooler. KkK K27 7200 turbo running, greddy blow off valve, tial F41 wastegate. 930 j pipe.

99 % street use (for now).

Is this a good / appropriate setup?

Feedback appreciated.


Chris
89 G50 Carerra

[quattrorunner]

Ya that setup is pretty well known to make 350-380hp.

[cmcfaul]

.5 bar a good starting point?
Anything I should consider changing or upgrading?

Thanks,

Chris

[quattrorunner]

Originally Posted by cmcfaul

.5 bar a good starting point?
Anything I should consider changing or upgrading?

Thanks,

Chris

Todd Knighton of Protomotive has the answers.

[Raceboy]

0.5 bar on 3.2 does not require any engine mods, you only need to assure you have good control over fuel mixture and ignition angle.

[Geronimo]

Isn't the real question how many days with the 915 last

[cmcfaul]

89 Carrera has the G50 with LSD. Way stronger than the 915.

I am hoping to just change the Motronics chip to address mixture and timing. Hoping there is an out of the box solution on that front. Am I over simplifying?

Will bigger injectors be needed?

Thanks,

Chris

89 G50 Carrera

[juan ruiz]

.5 non-adjustable boost + fuel pressure regulator + small turbo + chip , no internal modifications, non-intercooler will be 320rwhp.

[cmcfaul]

Sounds about right. Will have an IC. Have not seen it yet but think it's a full bay.

['76 911S 3.0]

FWIW, I used an aftermarket Evo X intercooler and had the inlet rotated 90° so it pointed down rather than out towards the driver side. Also had the mounting tabs added, but other than that it fits well and air temps are always ambient.





Modification to the ducktail:





Here you can see the original configuration of the intercooler inlet:

[Rodsrsr]

Its a little bit of work but if you can shove the intercooler further back it will fit under the ducktail by just modifying the opening.

[Bucketlist]

[QUOTE=Rodsrsr;10176264]Its a little bit of work but if you can shove the intercooler further back it will fit under the ducktail by just modifying the opening.

Or get a DP style lid: