3.2SS Turbo Build

['76 911S 3.0]

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.



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.





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.



Initial exhaust config (waaaay too loud):



Wisecraft Fabrication art:









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



Open to thoughts, comments, and critiques!

[DeltaBravo]

! Beautiful.


Sent from my iPhone using Tapatalk

[Tippy]

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

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

[danco_]

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!

[Tippy]

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.

['76 911S 3.0]

Originally Posted by DeltaBravo

! Beautiful.


Sent from my iPhone using Tapatalk

Thanks!

Originally Posted by Tippy

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

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

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.

[Tippy]

Originally Posted by '76 911S 3.0

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.

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...

['76 911S 3.0]

Originally Posted by Tippy

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.

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.

Originally Posted by danco_

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!

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



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:

['76 911S 3.0]

Originally Posted by Tippy

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...

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...

[Tippy]

Originally Posted by '76 911S 3.0

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.....

['76 911S 3.0]

Originally Posted by Tippy

Nice boost threashold!

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

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

[Tippy]

It happens

[danco_]

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

[Geronimo '74]

Love the color matching cookie cutters too.

[Flojo]

WOW!

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

['76 911S 3.0]

Originally Posted by danco_

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

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

Originally Posted by Geronimo '74

Love the color matching cookie cutters too.

Thanks! Those came like that from the factory!

Originally Posted by Flojo

WOW!

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

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

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



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

[bigel]

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!

[75 911s]

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.

[Flynt]

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.

['76 911S 3.0]

Originally Posted by bigel

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!

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.

Originally Posted by 75 911s

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 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.

Originally Posted by Flynt

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.

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!