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Welding finished on the Air Flow Meter Bonnet...............Just need to be cleaned up some and painted black....

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1980 SC Flatnose, Euro 3.0, LW Flywheel, 993 Cams, Port & Polish Heads, RS Cut Valves, MSD 6AL, Blaster Coil, Magnacor Leads, Boxster Brakes, WEVO Mounts, TRG Roll Bars, Rollcage, RSR rear fenders, OE Short Sift, K27 7200 Turbo Conversion, OBX Headers, Tial Wastegate, EFI MicroSquirt v3
Old 01-26-2013, 10:40 AM
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Very nice piece.

Weldings look good and the lip turned out great.

Bodes well
Old 01-26-2013, 01:22 PM
  Pelican Parts Technical Article Directory    Reply With Quote #42 (permalink)
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Gavin,
I like the bonnet. How are you going to attach it?
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Old 01-26-2013, 03:36 PM
  Pelican Parts Technical Article Directory    Reply With Quote #43 (permalink)
Bad LT
 
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Have you bought an electric oil pump yet? I am starting to look for one now myself.
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3.3 with ported heads,964 cams,3.2 manifold, Haltech EFI,WTA intercooler,BW366,Fabspeed headers,TIAL gate and ARP studs other than that it's completly stock.
Old 01-27-2013, 03:56 AM
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The bonnet has been welded inside and out so fingers crossed it is air tight.

I've got some 127mm Silicone coupler so will cut that down to the correct height and use 2 x jubilee clips to hold it on just as SOK did with there very similar version.
There is a welded and smoothed lip on the bonnet and also a lip on the factory Air Flow Meter so that should stop the bonnet from lifting...

I got the oil scavenger pump from eBay :

NEW Electric Oil Scavenge Pump for Remote Low Rear Mount Turbo Return Line 12v | eBay
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1980 SC Flatnose, Euro 3.0, LW Flywheel, 993 Cams, Port & Polish Heads, RS Cut Valves, MSD 6AL, Blaster Coil, Magnacor Leads, Boxster Brakes, WEVO Mounts, TRG Roll Bars, Rollcage, RSR rear fenders, OE Short Sift, K27 7200 Turbo Conversion, OBX Headers, Tial Wastegate, EFI MicroSquirt v3

Last edited by gavinc69; 01-27-2013 at 01:30 PM..
Old 01-27-2013, 01:13 PM
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Bad LT
 
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Thanks for the link. I was thinking of one of these.
Tilton 40-525 Cooling Kit Differential Oil Pump 12 V DC Kit | eBay

While I am here. Where are you planning to get your oil feed for the turbo from and where are you going to feed it back to? Pics?
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3.3 with ported heads,964 cams,3.2 manifold, Haltech EFI,WTA intercooler,BW366,Fabspeed headers,TIAL gate and ARP studs other than that it's completly stock.

Last edited by Uncle; 01-28-2013 at 01:35 AM..
Old 01-28-2013, 01:22 AM
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Its good to have a lip on anything that is pressurized; otherwise, you have couplers that come off. I had that problem until I finally had beads welded to form a lip.
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Old 01-28-2013, 09:46 AM
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The oil feed is from the oil pressure switch located at the top back (opposite fan end) of the engine, its the location the 930 use's.
I've purchased a kit from TurboKraft for the 930 that replaces the factory kit and included an oil limiter to help stop the turbo smoke on start up.


TurboKraft : Catalog Home : Turbocharger Oil Feed Line Set : 3K-Warner [930 CVS BWK TK] - $205.00


Oil will be returned back to the oil tank.
I'll get pics posted as I do it.


I will be getting lips added to all me ally pipe work ounce i've got the correct lengths cut and tested.
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1980 SC Flatnose, Euro 3.0, LW Flywheel, 993 Cams, Port & Polish Heads, RS Cut Valves, MSD 6AL, Blaster Coil, Magnacor Leads, Boxster Brakes, WEVO Mounts, TRG Roll Bars, Rollcage, RSR rear fenders, OE Short Sift, K27 7200 Turbo Conversion, OBX Headers, Tial Wastegate, EFI MicroSquirt v3

Last edited by gavinc69; 01-28-2013 at 10:27 AM..
Old 01-28-2013, 10:21 AM
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Steel bonnet cleaned and ready for paint.....








One side carbon block off installed.....




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1980 SC Flatnose, Euro 3.0, LW Flywheel, 993 Cams, Port & Polish Heads, RS Cut Valves, MSD 6AL, Blaster Coil, Magnacor Leads, Boxster Brakes, WEVO Mounts, TRG Roll Bars, Rollcage, RSR rear fenders, OE Short Sift, K27 7200 Turbo Conversion, OBX Headers, Tial Wastegate, EFI MicroSquirt v3
Old 02-03-2013, 01:05 PM
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Looks great.
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Old 02-03-2013, 06:28 PM
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Started working on the install this weekend.

So far, the old Fabspped exhaust has been removed.
I then installed the OBX headers. The only issue I found was a small lip on the headers didn't allow them to fit flush to the bottom of the engine and the exhaust studs to stick out past the flange far enough to get a nut on. So I just cut off the lip and ground it so the top flange was nice and flat. Once all six where done the headers fitted fine, no problems at all.
Next I fitted the Tial wastegate and the wstegate dump pipe, I had to cut the pipe short as it was a generic length.







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1980 SC Flatnose, Euro 3.0, LW Flywheel, 993 Cams, Port & Polish Heads, RS Cut Valves, MSD 6AL, Blaster Coil, Magnacor Leads, Boxster Brakes, WEVO Mounts, TRG Roll Bars, Rollcage, RSR rear fenders, OE Short Sift, K27 7200 Turbo Conversion, OBX Headers, Tial Wastegate, EFI MicroSquirt v3

Last edited by gavinc69; 03-03-2013 at 01:04 PM..
Old 03-03-2013, 12:53 PM
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1980 SC Flatnose, Euro 3.0, LW Flywheel, 993 Cams, Port & Polish Heads, RS Cut Valves, MSD 6AL, Blaster Coil, Magnacor Leads, Boxster Brakes, WEVO Mounts, TRG Roll Bars, Rollcage, RSR rear fenders, OE Short Sift, K27 7200 Turbo Conversion, OBX Headers, Tial Wastegate, EFI MicroSquirt v3
Old 03-03-2013, 12:56 PM
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man, must have some casual laws there if you can run a screamer pipe!
Good project though, am following with interest.
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this time for sure...
Old 03-03-2013, 04:35 PM
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I had the same flange problem with my GSF headers on my SC motor. Quick grind and file had it sorted.
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3.3 with ported heads,964 cams,3.2 manifold, Haltech EFI,WTA intercooler,BW366,Fabspeed headers,TIAL gate and ARP studs other than that it's completly stock.
Old 03-04-2013, 07:30 PM
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Glad I'm not the only one having to grind off the lip then..

The Fabspeed Supercup exhaust system that was on the car was quite loud so hopefully the Zork won't be too much louder or even as loud.
I've only ever heard Zorks on Youtube so have no first hand experience as to the noise!!!

I will be dropping the engine this weekend to install most other bits including the oil feed line and vacuum connections on the back of the throttle body.

Will get photos done as I progress
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1980 SC Flatnose, Euro 3.0, LW Flywheel, 993 Cams, Port & Polish Heads, RS Cut Valves, MSD 6AL, Blaster Coil, Magnacor Leads, Boxster Brakes, WEVO Mounts, TRG Roll Bars, Rollcage, RSR rear fenders, OE Short Sift, K27 7200 Turbo Conversion, OBX Headers, Tial Wastegate, EFI MicroSquirt v3
Old 03-05-2013, 02:04 PM
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Looking forward to the photo's. Sounds like you're about a week ahead of me. I'm just waiting on my 3.2ltr manifold to come. Have mounted the Turbo and gate and started to plumb the fuel system.
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3.3 with ported heads,964 cams,3.2 manifold, Haltech EFI,WTA intercooler,BW366,Fabspeed headers,TIAL gate and ARP studs other than that it's completly stock.
Old 03-05-2013, 02:49 PM
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Engine is out so I popped over to have a quick look on the way home from work
and look at the rear of the throttle body to get an idea of what vacuum connections
I need to cap off etc :



The Decel Valve has to be removed so I will cap off the two larger connections.
The Thermo Valve sits in between the Decel Vavle and the Warm Up Regulator and
still need to be connected, so I will disconnect it from the Decel Valve to plug it directly into the Throttle Body. This looks like the same others have done in there posts.

One of the two small vacuum ports next to each other is already capped off.
The other port runs down to the Distributor Cap so i'm thinking this needs to be left connected!

There are also two connections on the front of the Throttle Body :




The lower smaller port runs down to the Distributor Cap but it has been capped off and has been like this as long as I remember.

The larger port runs to the top of the Warm Up Regulator so again I'll leave this as it.

If anyone has any info or other advice on these connections please let me know, thanks
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1980 SC Flatnose, Euro 3.0, LW Flywheel, 993 Cams, Port & Polish Heads, RS Cut Valves, MSD 6AL, Blaster Coil, Magnacor Leads, Boxster Brakes, WEVO Mounts, TRG Roll Bars, Rollcage, RSR rear fenders, OE Short Sift, K27 7200 Turbo Conversion, OBX Headers, Tial Wastegate, EFI MicroSquirt v3
Old 03-06-2013, 12:15 PM
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Got some major progress today, I'm well happy with the results so far seeing as I don't really know what I'm doing!

Only real problem so far is it appears the Turbo is sitting way higher than normal.
No idea why! No one else's threads seem to report this.

I have had to cut loads out of the rear tin ware to get round the turbo. I will make
a plate formed to fit over the turbo and fill in the gaping hole on the tin ware.
And due to the location of the turbo I will install heat shielding material above the turbo, below the tin ware.

The genuine turbo bracket does also not fit correctly so I will have to modify that to fir also!










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1980 SC Flatnose, Euro 3.0, LW Flywheel, 993 Cams, Port & Polish Heads, RS Cut Valves, MSD 6AL, Blaster Coil, Magnacor Leads, Boxster Brakes, WEVO Mounts, TRG Roll Bars, Rollcage, RSR rear fenders, OE Short Sift, K27 7200 Turbo Conversion, OBX Headers, Tial Wastegate, EFI MicroSquirt v3

Last edited by gavinc69; 03-09-2013 at 11:53 AM..
Old 03-09-2013, 11:44 AM
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1980 SC Flatnose, Euro 3.0, LW Flywheel, 993 Cams, Port & Polish Heads, RS Cut Valves, MSD 6AL, Blaster Coil, Magnacor Leads, Boxster Brakes, WEVO Mounts, TRG Roll Bars, Rollcage, RSR rear fenders, OE Short Sift, K27 7200 Turbo Conversion, OBX Headers, Tial Wastegate, EFI MicroSquirt v3
Old 03-09-2013, 11:47 AM
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1980 SC Flatnose, Euro 3.0, LW Flywheel, 993 Cams, Port & Polish Heads, RS Cut Valves, MSD 6AL, Blaster Coil, Magnacor Leads, Boxster Brakes, WEVO Mounts, TRG Roll Bars, Rollcage, RSR rear fenders, OE Short Sift, K27 7200 Turbo Conversion, OBX Headers, Tial Wastegate, EFI MicroSquirt v3
Old 03-09-2013, 11:51 AM
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