3.2SS Turbo Build
 

Well I think it's finally time I posted my build thread. A little background on the car and myself. The chassis is a Signature Edition (however far from original, all I have that remain from the Signature Edition are the color, wheels, and steering wheel) originally owned by my grandfather who purchased the car as the second owner in 1978. After driving the car for a few years, he swapped the engine for a 1979 SC engine and pretty much left the car untouched after that. My father then acquired the car, with the intent of making the car his track car and amassed a pile of parts that never made it onto the car.

http://forums.pelicanparts.com/uploa...1531763556.jpg

Eventually, the vehicle came into my possession in 2002. I parked the car from 2004 to 2014 and did not touch it while I completed college and the early stages of my engineering career. In 2014 I decided to tackle the car and begin working on everything I had always wanted to do but could never afford. Luckily for me, I picked the perfect time to start the project as prices for parts were beginning to skyrocket.

I had always wanted to build a 3.2SS from the 3.0 and I decided to tackle that project first. Fast forward 2.5 years and I start the engine for the first time with CIS, quickly realizing there was still more work to be done. Shortly there after, I started work for AEM Performance Electronics and quickly decided to convert the engine from CIS to EFI using the AEM Infinity. A little help from Rasant Products with his EPM adapter got the project underway. I ditched the CIS manifold for a Carrera Intake, made my own fuel rails, wiring harness, and a few other items needed to complete the project. 1 year later, the converted engine makes it maiden voyage on a 700-mile round trip to Rennsport Reunion V without a hiccup. Power on the Mustang Dyno at the office resulted in 204 WTQ and 194 WHP. Not bad but I wanted more.

http://forums.pelicanparts.com/uploa...1531763720.jpg

http://forums.pelicanparts.com/uploa...1531763629.jpg

I have always wanted to turbocharge the engine and after talking with a few manufacturers, I decided to bite the bullet. I found a set of used B&B turbo headers that I modified for a T4 flange and a Tial 44mm V-band wastegate. Borg Warner supplied me with a S360 turbo and I utilized a prototype Evo X intercooler we had lying around in a scrap bin at the office (sealed charge pipe inlet and oulet so no debris was inside). I fabricated a few parts here and there including a brace for the turbo as well as the engine tin piece. A Turbowerx electric scavenge pump was utilized with a drip tank I fabricated. Chris from Wisecraft Fabrication in Orange County put the icing on the cake with a beautiful exhaust built to my request. I still have yet to dyno tune the engine at this stage, but will in the near future.

http://forums.pelicanparts.com/uploa...1531763794.jpg

Initial exhaust config (waaaay too loud):

http://forums.pelicanparts.com/uploa...1531763779.jpg

Wisecraft Fabrication art:

http://forums.pelicanparts.com/uploa...1531763863.jpg

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http://forums.pelicanparts.com/uploa...1531763958.jpg

http://forums.pelicanparts.com/uploa...1531764029.jpg

I wanted a 934-esque exhaust, but out the original exit rather than center. I think Chris pulled this off perfectly:

http://forums.pelicanparts.com/uploa...1531764249.jpg

Open to thoughts, comments, and critiques!

[emoji50]! Beautiful.


Sent from my iPhone using Tapatalk

No critique here as everything is awesome........except the 915 trans.

Might have a short life behind that beast of an engine.

Fantastic!

I'd love to get a ride in this thing. I've been considering turbo for the last three months but have yet to pull the trigger.

9.5:1 seems fairly high compression with no knock sensors or twin plug. Any issues on hot days? Are you running a turbo tail to fit that cooler? Cheers!

I'd admit, I got excited when I saw you mention an Evo X IC fits. Clearly you had to modify the inlet 90 degrees.

I did something similar. I bought a Treadstone V8 IC good to 1300hp. I had to lop off both the inlet and outlet pipes and reorient to match the 911 configuration, but it was well work it.

Thanks!

I am counting down the days and simultaneously saving my pennies for a 930 trans (short or modified long bell housing) in preparation for the inevitable. :rolleyes:

It is what it is...


Curious how you like the S360? That is one great turbo!

I'm happy with my S366, and am wanting the S369, or possibly a burly S475. HP is like crack to me... :D

Correct, the left hand tank had to have the inlet rotated 90 degrees but overall not too much effort to make it work. Inlet temps are ambient all the time when moving, they will creep when the car is stationary but drop right back down once the vehicle is moving again. I was originally going to run non-IC but very happy I opted against that route.

Absolutely, any time! There is a knock sensor on the engine, works quite well (on the throttle linkage stud in right of this image):

http://forums.pelicanparts.com/uploa...1531767426.jpg

I also run a blend of E85 and pump to help keep the knock threshold of the fuel in check. I also have an Elephant Racing widemouth cooler in the fender with a temp activated fan. I never see oil temps above 190F, even in stop and go traffic with an ambient temp near 90F.

I cut the duck to fit the intercooler:

http://forums.pelicanparts.com/uploa...1531767542.jpg

http://forums.pelicanparts.com/uploa...1531767559.jpg

I love the S360, I have the 0.92 A/R T4 divided hot side and see 10 psi by about 3000 rpm. I must say, the spool noise from these BW's is highly addicting and the turbo itself is a very robust unit. It is a very tight fit back there tho, but it fits...barely. I'm already contemplating upgrading to the S366 SXE for the 360 degree thrust bearing and billet comp wheel alone...

Nice boost threashold!

The 'jet engine' sound is goosebump inducing to me..... :cool:

Agreed! I am annihilating my fuel economy because I am constantly on/off throttle just to hear that jet engine sound :D

It happens

Dude I'd love to link up and buy you lunch if I can get a ride in this thing.

I think a ride in your car will be enough to push me over the edge and completely gut my future kids' college fund. The kids don't exist yet so I'm sure they won't be mad.

Cheers,
Ryan

Love the color matching cookie cutters too.

WOW!

I guess that rear bumper now needs some extra heat protection.
Doing that, you could kick those massive bumperblocks.

Haha let me get some minor details sorted and we'll for sure link up and I'll take you for a ride.

Thanks! Those came like that from the factory!

There is some heat protection in there, it's just hidden ;)

This also lines the entire inside of the bumper, DEI Heat Screen.

http://forums.pelicanparts.com/uploa...1531869689.jpg

Here is some more from when I built the turbo brace and modified the engine tin:

http://forums.pelicanparts.com/uploa...1531869757.jpg

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That is something else, my friend. Did you mention what the resulting HP is with the additioin of the turbo, headers, etc.?

Good luck to you Jayson!

What a fun build. Probably a bit scary on those 6" cookies in back. Total sleeper with those matching sugar scoops and cookies. It'd be really cool if you could get a custom intercooler built that fits under the original decklid - I've seen it done.

Add bigger rear wheels and tires to your turbo trans wishes. :-D If you were really trick, you could buy 2 more 6" cookies, have them widened to 7" wheels with a 32mm offset. Then you could run a 225/50 in back.

I love the stock look, down to the cookies. And true narrow body - not even Carrera flares!
Contemplating something similar for my purple '75.
I have questions.. Does the back step out on you when you hit full boost? Do you feel like the car is still "balanced" with so much power on tap? Do you have any brake or suspension upgrades?

If you're ever in San Diego I'd stand in line for a ride.

Hasn't been on the dyno yet, been sorting out a few minor issues and waiting for the exhaust to be completed. Have an oil leak to fix up and then I'll be ready for the dyno in the coming weeks. Goal is to be right around 350WHP or less. Engine is on a very safe and conservative tune at the moment. I estimate the power to be about 250-275whp at the moment.

I know TK makes one that fits under the duck and will tailor the design to your individual needs; however, I can't justify spending over $2k for one when I have something that works well and doesn't look half bad. Air temps never go above ambient with this configuration unless the vehicle is stationary.

I have a set of 944 7" cookies but would like to get them color matched before I run them. Surprisingly with the R888 tires in 205 width I do not have traction issues. I do plan to run a boost by gear configuration with the Infinity so gears 1-2 run off spring pressure (5 psi), 3rd gear sees 7psi, and gears 4-5 see 10psi. Currently, I have boost control disabled and am running strictly on spring pressure.

That was the idea! I love the idea of a total sleeper. Currently I do not have traction issues but I am running low boost and a conservative tune. We will see how it changes after the dyno session. I will be sure to post a video of the dyno once I get to that point.

As far as suspension, the car has Koni's, adjustable sway bars front and rear, stock torsion bars, and Stoptech Level 2A brakes in the front with matching pad compound in the rear but with stock rotors and calipers. I'll be sure to let you know if I make down to SD!

http://forums.pelicanparts.com/uploa...1531937904.jpg

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.

Also, curious how the 915 is holding up :)

Nice build!

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.

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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.

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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:

http://forums.pelicanparts.com/uploa...1554413185.JPG

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http://forums.pelicanparts.com/uploa...1554413185.JPG

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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 :D

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. http://forums.pelicanparts.com/support/smileys/wat6.gif

Got some new goodies today in the mail :D

http://forums.pelicanparts.com/uploa...1554506881.jpg

http://forums.pelicanparts.com/uploa...1554506881.jpg

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

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:

http://forums.pelicanparts.com/uploa...1572824649.jpg

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.

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

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http://forums.pelicanparts.com/uploa...1585690953.JPG

http://forums.pelicanparts.com/uploa...1585690953.JPG

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

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):

http://forums.pelicanparts.com/uploa...1585692259.jpg

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.

Some updates:

Trans all cleaned up:

http://forums.pelicanparts.com/uploa...1589915066.JPG

http://forums.pelicanparts.com/uploa...1589915066.JPG

http://forums.pelicanparts.com/uploa...1589915066.JPG

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

http://forums.pelicanparts.com/uploa...1589915129.JPG

http://forums.pelicanparts.com/uploa...1589915129.JPG

Turbine housing ceramic coated:

http://forums.pelicanparts.com/uploa...1589915162.JPG

http://forums.pelicanparts.com/uploa...1589915162.JPG

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

http://forums.pelicanparts.com/uploa...1589915227.jpg

http://forums.pelicanparts.com/uploa...1589915227.jpg

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

http://forums.pelicanparts.com/uploa...1589915266.JPG

Swapped out the stock rods for some Carrillo units:

http://forums.pelicanparts.com/uploa...1589915305.jpg

http://forums.pelicanparts.com/uploa...1589915305.jpg

Just about ready to start putting everything back together :D

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

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

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.

http://forums.pelicanparts.com/uploa...1627930495.jpg

http://forums.pelicanparts.com/uploa...1627930596.jpg

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

http://forums.pelicanparts.com/uploa...1627930701.jpg

http://forums.pelicanparts.com/uploa...1627930701.jpg

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:
http://forums.pelicanparts.com/uploa...1627965207.jpg

CC'ing Combustion Chamber:
http://forums.pelicanparts.com/uploa...1627965207.jpg

http://forums.pelicanparts.com/uploa...1627965207.jpg

Case Halves Sealed Up:
http://forums.pelicanparts.com/uploa...1627965207.jpg

Cylinder Heads:
http://forums.pelicanparts.com/uploa...1627965207.jpg

Prototype Cam/Crank Trigger:
http://forums.pelicanparts.com/uploa...1627965207.jpg

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 :rolleyes:

https://youtu.be/wtd1UVcF5f4