3.2SS Turbo Build

[Geronimo]

So many great turbo builds I keep running across. How is the car doing to date? I'm trying to take in all the learnings I can from all the builds before I jump into the boost water.

[stownsen914]

Also, curious how the 915 is holding up

Nice build!

['76 911S 3.0]

A bit slow going at the moment, recently had a baby so the car has been put on the back burner of sorts. I had a mis-shift late last year (bent 4 exhaust valves) and the engine is completely torn down again.









I sourced a set of heads from a member on this site and have been working on those. Made a set of inserts for the exhaust ports since the new heads have a receiver groove in them that my headers do not have. These are a press-fit and sit proud of the gaskets 0.001" for a minor crush. Also removed all the old and crusty exhaust manifold studs.

['76 911S 3.0]

I then turned my attention to the intake ports and designed and 3D printed a jig for a mill to match the injector notch on the CIS heads to the 3.2 intake manifold:









I also have a set of ARP Head Studs on order since I'm in there, and all the bearings are being replaced for good measure.

915 is holding up okay for now, not sure how it's going to do when we turn the boost up when it's all back together

[Geronimo]

That jig is cool, I was wondering about that as I have planned to get a 3.2 intake to replace my PMO's if I go turbo.

['76 911S 3.0]

Originally Posted by Geronimo

That jig is cool, I was wondering about that as I have planned to get a 3.2 intake to replace my PMO's if I go turbo.

I'm more than willing to loan it out if anyone would like to use it.

['76 911S 3.0]

Got some new goodies today in the mail





Should have done this the first time around but live and learn...then get Luvs.

[pampadori]

Do you include a dab of loctite, or no loctite?
I used those head studs and did one valve adjust since and everything was pretty tight. But I've heard others ha e noticed the studs loosen some.

['76 911S 3.0]

Originally Posted by pampadori

Do you include a dab of loctite, or no loctite?
I used those head studs and did one valve adjust since and everything was pretty tight. But I've heard others ha e noticed the studs loosen some.

I'll be adding some Loctite to mine upon installation, just for good measure.

Heads are done with AASCO springs and Ti retainers, machine work done at Vellios Machine Shop. Also had them chamfer the heads for the 98mm bore. Not entirely sure it was necessary with the JE's but opted to have it done anyway.

I hung the rods today, stretched the ARP bolts to spec. Using Mahle/Clevite race bearing shells on the rods this time around:



Crank was magnafluxed and polished at Engine Machine Services in Inglewood.

Next stage is cleaning/prepping the case for reassembly. Slowly getting there, hard to find time with a youngin' around.

['76 911S 3.0]

Cleaned up the trans a little bit this weekend so it's easier to see all the bits when it grenades!







Still have a lot more work to do on it, this was just a couple quick degreaser soaks and rinses.

['76 911S 3.0]

Also designed my own crank sensor mount that allows the distributor to be retained for the AEM EPM as my cam signal while using a Clewett 60-2 trigger wheel on a GSF pulley. Final part was CNC machined and anodized (I have a few extras too if anyone is interested):

[pampadori]

why are you switching to the Clewett crank pickup instead of the EPM?

['76 911S 3.0]

Originally Posted by pampadori

why are you switching to the Clewett crank pickup instead of the EPM?

Just want a little more resolution on the crank signal is all, no issues with the EPM.

['76 911S 3.0]

Some updates:

Trans all cleaned up:







Lower valve covers powder coated (uppers will be revealed at a later date):





Turbine housing ceramic coated:

['76 911S 3.0]

Intermediate shaft bearings (Genuine Porsche) with WPC Treatment for increased durability and longevity:





Repurposed my no-longer-used fog light switch as a 4 position engine map switch:



Swapped out the stock rods for some Carrillo units:





Just about ready to start putting everything back together

Stock rods with ARP bolts and Canyon one piece pin bushings will be for sale soon as well.

[LukasM]

Very nice and cool build Jayson! Did you ever get it completed? How does the short stroke engine run with a modern turbo on it, and what are you using as a redline?

Cheers,
Lukas

['76 911S 3.0]

Hi Lukas,

The engine is back together and getting some of the finer details ironed out. With the addition of the ring inserts on the exhaust ports I've had to ensure the mating flanges for the header are perfectly flat and that has been troublesome for the machine shop I brought them to so taking them elsewhere in the hopes it can get sorted. I have 2 flanges that are still not perfectly flat (verified this Prussian Blue and torquing the headers to the heads). Once that is all sorted, the headers will go off to ceramic coating and then everything can begin getting assembled.

I had the builder retard the mechanical cam timing just a bit from spec, 1.1mm vs. 1.26mm (964 cams) to shift the power band higher and keep the torque low to help try and keep the 915 in one piece.

Also had the waste gate run shortened up quite a bit as I am not concerned about it being located in the factory 930 location.

['76 911S 3.0]

Some additional photos from rebuild. I'll post more details about what all has gone into this later this evening.

['76 911S 3.0]

Engine Build Sheet:

Case:
3.0L Case
930 Piston Squirters
Genuine Porsche Intermediate Shaft Bearings, WPC Treated
964 Oil Pump
New Size 0 Intermediate Shaft Gear
New Chains, Guides
Carrera Chain Tensioners
ARP Head Studs

Crank:
3.0L Crank by Castillo's Crankshaft
Maganfluxed
Cross Drilled and Grooved Center Main
Plugs Drilled, Internal Passages Cleaned
Balanced
Heat Treated
Micropolished

Rotating Assembly:
Carrillo H-Beam Connecting Rods with WMC Bolts
Clevite Coated Rod Bearings
996 GT3 Main Bearings, WPC Treated
JE 9.5:1 Pistons

Cylinder Heads:
Late SC Heads, Intake Ported to 39mm
AASCO Valve Springs
AASCO Ti Retainers
964 Cams (set to 1.1mm lift)

Air Flow:
B&B 930 Headers (No Heat)- T4 Flange, Relocated 45mm Wastegate
Carrera 3.2 Intake Manifold
Borg Warner S360 Turbo
Turbosmart GenV 45mm Hypergate
Turbosmart RacePort BOV
EvoX Garrett Intercooler Core - Modified Endtanks
Exhaust by WiseCraft Fabrication

Fueling/Spark:
ID 725cc Injectors
Flex Fuel Sensor
Home Made Fuel Rails
AEM 400 LPH Inline Fuel Pump mounted in 034Motorsports 1L Surge Tank
AEM Fuel Pressure Regulator
AEM Infinity
AEM SS Sensors for Fuel Pressure, Oil Pressure and MAP
AEM Oil Temp Sensor, Intake Air Temp Sensor
Turbokraft Cylinder Head Temp Sensor Kit
Turbokraft TPS Sensor Kit
Bosch Knock Sensor
Toyota Sienna V6 Coilpacks


All Loaded Up and Off to Build:


CC'ing Combustion Chamber:




Case Halves Sealed Up:


Cylinder Heads:


Prototype Cam/Crank Trigger:

['76 911S 3.0]

A few videos before I eff'd up:

https://youtu.be/pO02gT8_nAE

https://youtu.be/4-SxCkhs8dI

And the video of me grabbing 3-2 rather than 3-4

https://youtu.be/wtd1UVcF5f4