Convinced I am screwed, Desperate!

lendaddy · 05:08 AM

Another 5 hour night spent in the garage pondering, drinking, adjusting, measuring, drinking, pontificating, drinking, screaming, wanting to smash, drinking, etc..

Something is very wrong with my exhaust setup. Under no circumstances can I get the turbo to be in the "right place". Is there any kind of template that can be used to setup where and at what angle the turbo flange should be at for everything to work? See the picture below. According to my research Porsche changed over the years, the Turbo mount, muffler bracket, front engine plate, and I am not sure about the front sheet metal. So does the bracket I have work with the front cover I have? Who knows, how would you? Does my muffler bracket work with everything else? Again it would appear not. If I hook up the turbo to the turbo flange of the exhaust and the muffler to the turbo(without using the turbo support bracket), the muffler is at a scewed angle and wants to hit the front plate. Whatever, I am probably only making sense to me, so my point is I need a template for the proper positioning of the turbo exhaust flange then I can cut and weld. Is this insane or what? The exhaust is supposedly a stock '85 930 system. Why isn't this working? I am getting angry again just thinking about it! aaaaaaaaaaaaaaaa

Just edited, I will send $100 to anyone that makes me a template (from the engine case or something that cannot be subjective to model year BS) to the top of the turbo flange showing the proper angle, height, etc.. The perfect jig would bolt to the turbo flange and some imovable non subjective part of the case. Thanks

lendaddy · 05-09-2003, 06:22 AM

100 views and not one response? Gotta bump, sorry.

As additional info, I am using a Monty dual out muffler so both tips need to be parrallel which I cannot get from the current angle of the turbo mount. So something is wrong. Did the actual turbo pipe change over the years as well? This one does NOT appear bent at all.

David E. Clark · 05-09-2003, 06:44 AM

If there is a "hot rod" shop in your area they should be able to fabricate whatever you need. Most "hot rods" have a custom exhaust so these guys are usually pretty good at fabricating custom mounting brackets. Just a thought. Good Luck.

David
'73 911E

lendaddy · 05-09-2003, 06:57 AM

It's not that I couldn't put it "somewhere" and make it work. Its that I need the exhaust tips to exit in the correct location in the rear valance. Athough I could mount the motor, measure, drop the motor, cut and tack weld, mount the motor, varify and modify, drop the motor, finish weld, and finally permanantly mount the motor, I would really rather not. I used a stock exhaust system just to avoid all this crap. There simply has to be a "correct" location for the exhaust turbo flange. This is weiging heavily on me and I cannot think of anything else all day. Combine that with all the gurus saying "you can easily swap a later exhaust to rid yourself of the reactors" and I think you will understand my pain. I am starting to think I am cursed. I know I am pissed!

lendaddy · 07:02 AM

One last idea that just hit me. The two heat exchangers are supposed to be identical, but what if they are not? What if I have them switched? I know this is a long shot, as the both had the cut-out for the clutch horshoe spring.

Nope, just checked and there is only one part# for both.

gadams · 05-09-2003, 07:04 AM

you have a PM

greg

Superman · 05-09-2003, 07:06 AM

Two suggestions and a thought. JW can probably handle this job with his eyes closed and would probably know exactly what your problem is. Also, it is true that hot rod guys and exhaust shops are very handy with tools like oxy/acetylene torches and MIG welders. They can do magic with those tools, quickly and inexpensively.

My final thought is that late at night, after drinking a bit, it's easy for me to get a bit irritable. At these times, I am not very good at solving problems or putting things in perspective.

john walker's workshop · 05-09-2003, 07:08 AM

those turbo pipes get bent from rear end collisions. i had the same thing happen on an engine here recently. the original was toast from the wreck, so i bought another used one and that fit the same as yours. the next one i found fit fine. looking at them, it's real hard to tell if they're bent or not. if it was just too close to the center engine mount console, a port-a-power could bend it outward, but if the flange is on the wrong angle, then it's either cut and weld, or find a better one.

lendaddy · 05-09-2003, 07:18 AM

Ok now we are getting somewhere. Thanks. I bet you are right about the rear end collision as I got the system from a dismantler. I have a porta power so I guess what harm can be done right. JW, one question. I was given a later stlye turbo mount from another Pelican. Only the bottom two mounts can attach to my frontplate but it is still rigid when mounted. However when I mount just my muffler to this bracket the angle of the muffler is off quite a bit. Is my '77 front plate not compatible with this later style turbo mount? Thanks.

john walker's workshop · 05-09-2003, 08:49 AM

many people don't use that bracket on custom installations. the muffler just needs to be clamped to it's support bracket on the right end.

MyTurbo3.6 · 05-09-2003, 10:45 AM

lendaddy

Check out the attached picture...it is pretty obvious that your angles are significantly off...

911pcars · 05-09-2003, 01:17 PM

Lendaddy,
It seems you've posted this question several times before; also here and the threads seem to provide the same answers/solutions. Are you still searching for THE answer?

To review:
It looks like the turbo flange is off, yes?. As suggested before, remove the exhaust pipe leading to the turbine inlet section, install/reshape the turbo mount to line up the turbo to the factory sheet metal/compressor pipe, then have a muffler shop fix, bend or otherwise reshape the exhaust pipe so it lines up on both ends. Then do the same on the turbine outlet side.... or you can pull out the 6 foot pry bar (or PortaPower) and muscle it in place. What sounds better to you?

Just trying to help,
Sherwood