Project Turbo 69` In The Making. Suggestions Welcome
 

O.K. guys here`s my latest project(as if I have time to do all this work). I purchased this 95% rust free half ass`ed modified coupe so I could spare my present fully finished R/S replica the pain of all this chopping up.

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After a full chassis inspection I decided it could use a new set of floors. They hadnt rusted through but was not far from it.

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Then decided a 964 rear decklid would be nice addition to the car(turbo motor swap was not in the plan at this time).

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To be continued............

Then found some defects in the welding on the previously installed carrera rear flares. I had to strip the body filler and weld them on properly. This picture is before my repair(forgot to take pics of the revised welding)

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Luckily the car had a beautiful rustfree factory steel S spoiler . I stripped it to bare metal welded the bumper gaurd holes closed and prepped it for paint. Also notice the steel rear bumper flares which are a perfect fit to the rear flares.

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To be continued......

Heres the picture that wouldnt load from the last post.

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Kurt Williams

Next project was the doors. Both of the doors on the car were loaded with body filler and quite honestly were junk even though they were not showing any defects. I had a near perfect set of 86` doors downstairs in the stockroom and figured its time to put them to good use. Funny thing is they were the same color and almost matched the body. Shown is a picture of one of my employee`s swaping out all the internals in favor of manual windows and aluminum trim . I had to make a curved plate of steel to weld inside the doors to cover the huge flag style mirror mounting holes. The car will get a period correct oe chrome unit instead.




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To be continued.....

Next was the door jams and hood jams. They were in terrible shape with chipped and flaking paint. After properly fitting(shimming and adjusting) the doors they were removed and out came the 180 grit sandpaper for over 10 hours of painful sanding. I then applied the german made U-POL epoxy primer($$$) to all the jams to assure they wont rust up while the project continued. The rest of the car was also primed and guide coated(block out for staightness). After doing this process 2 times the car is as straight as it can possibly be. Here`s a few pics of the car primed.

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To be continued.......

Door jams where painted this past week in an audi color called Nogaro blue. I love this color and so does everyone who has seen it so far on the jams. Included below is a picture of an audi in this color. Because its a pearl paint the camera does not do it justice. Cant wait to install the HRE 540 wheels I just bought on ebay against this color.
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&category=43957&item=24 32562559



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To be continued.... BTW sorry if some of you dont have high bandwidth.

Kurt Williams

Here`s the audi picture in same Nogaro blue .


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OK. Heres where the project picks up a little. I am going to check out a 92`3.3 C2 single turbo motor this week. I want to install it in this car. At this time the car has a great running 71` T 2.2 motor built to S specs with webers and is quite fast as is(you should feel it accelerate while fully gutted and without doors, interior, glass and hoods holy crap !!!), but does not hold my interest. Also the car has a type 911 5spd that decodes to an S model(engine and tranny will be for sale in about 1 month). The shame of it is I just bought a complete B&B header/muffler set up with dual out $$$$$ and now cant use it(I guess thats going to be a future ebay item).
What I need advise on it this. Which tranny should I use. I dont want to go with the G50 unit and the engine makes only 320hp.
I do have a late style short bell 930 4spd box sitting downstairs but have no idea what to do with a clutch . What would work ? Which shifter would I need. I have a new 930 turbo clutch cable in stock . Will that be needed ? Will an aluminum 915 unit hold up ? Also is the 92` 3.3 motor a reliable unit ? I havent heard any bad things but then I never paid any attention to find out.
Also wanted is a roll cage for this car. If anyone has one that would help. This project is starting to hurt the wallet a little !

I will be sending this car to the bodyshop (spraybooth)this coming week for full paint. More pictures to follow when it returns.

Kurt Williams

Kurt, cool project and excellent work. A fellow do-it-yourselfer! I can relate to the work involved, a few pics here and there just doesn't fully represent the hours. Are you planning on modifying the 3.3L turbo? As for trannys, I would suggest the turbo 4 speed if your not inclined to go G50. You've prabably driven a 915, they don't shift well at all no matter what you do. I beleive the 4 speeds are better but I've never driven one. The 915 is marginally strong enough. I twisted a fully rebuilt 915, in short order, before I switched to a G50. The 4 speeds are rock solid strong. You could re-gear if you want something shorter. I am running a KEP clutch setup (stage II if I remember correctly) and haven't had any problems yet but I'll let you know shortly when I get my twin turbo on the road. cheers.

Nice project and nice job.
I think you can use an early 930 clutch set up. I would think you would have to get a 930 shift ass. buy I'm not sure.
I don't know if a 915 would hold up. I didn't want to chance it with my car so I installed a G50.
I think any 930 motor is reliable.
Keep up posted

Any more suggestions ?

Don't '92 3.3 Turbo motors still use CIS? I think the 3.6 was the first of the Motronic-injected turbo motors.

I think they're fairly bulletproof. That colour looks great!! :)

Please post some more photos when you can!

Yes its the last of the cis. That makes life much easier.

OMG, Nogaro blue 911, how wierd. I was thinking about doing an RS replica after I got out of college in Nogaro blue.........well goddamnet, you beat me to it. Although this car seems more than worthy of what my original idea was =).

Kurt,

Thanks for the great pics of your craftsmanship. Love the color too.

Unbeliavebly, YES!

I really cannot fathom why...

Well......... I just got home (13hr trip) from picking up the 92` C2 turbo motor(with every component )from deep in the virginia horse country. Wow this motor is brand new !!!! I did a leakdown test and it showed less than 5% on all six cold ! The motor came from Kelly Moss who in turn purchased it from brumos porsche(florida) back in 93`Neither race team wanted it because the 3.6 had just become available to them. The guy was told it has no more than 2k miles on it . It looks like it was just pulled from a porsche engine crate. Every component looks as good as new. No filth other than light dust(I am so happy with this purchase). I purchased a bunch of other components along with the motor which include a huge custom made intercooler, 2 rebuilt 930 axles, 2 factory lightweight clutch assemblies, a complete 89` turbo exhaust(just for initial placment , will get the B&B setup), A fender mount C2 turbo oil cooler, An extra k27 turbo, and 15+ other things im too tired to remember.
Anyway , its still sitting in my truck and will be unloaded tomorrow. I will post some pictures ASAP.
Also the chassis left friday for the paint booth. Should be returned to me by this coming weekend.
I will be needing some further components to do this engine swap. I will list my needs in waynes classified section as well as here. BTW this is what I need as of now. I am open to suggestions from you guys since this is my first turbo swap into an early chassis.

Parts needed :

75-89 930 OIL TANK
930 POSI UNIT (stock is ok)
EURO 3.3 CIS INJECTION SETUP (better fuel flow and doesnt use O2 sensor/frequency valve)
930 trailing arms
930 COMPLETE DECKLID ASSEM (oe only)
OIL LINES TO THE FENDER MOUNT COOLER
BOTH 930 FUEL PUMPS
930/911 CIS FUEL TANK(like new only)

I can be reached directly at kurt@digitalprovisions.com

BTW could you guys beleive the wife knows about all this and is happy about it .

Kurt Williams

BTW guys I didnt take any pictures but this guys garage was unbelievable. Wish I had one like his. You could see your own image reflected off the garage floor. Plus the goods inside were nice unough to cause drooling . I was very impressed to say the least.

Kurt Williams

More power to ya but with everything you have done wouldn't it have been cheaper just to buy a nice used 930?

That way you would also have the better brakes and suspension to keep up with all that power.

Good luck with the CIS though. Most people are overly critical of it but it has the ability to flow a lot of air if you can add some additional fuel to it.

Instead of tracking down european distributors and tweaking the hell out of it you might just want to look at the following piggy back solution instead.

http://hksusa.com/products/?id=638

I have one going on my 930 when I get it back together.

I dont like the look of the 930 cars(no offense) . Yes I could have just bought a 930 but prefer the early cars by a landslide. I dont like the touring feel the 930`s have, nor do I find the huge flares attractive. The bumpers dont do it for me either. With this car I am building I get everything I want other than the fact that I cant fit a conservative decklid on it. Due to the intercooler clearance problem I will have to put that 964 non turbo decklid in stock rather than on the car. I wish there was a way to mount the intercooler somewhere else besides the top of the motor.
The CIS system is quite reliable and very simple as well as cheap. I will not boost this car past 1 bar so with 400hp or less the CIS will give me the best bang for the buck.
BTW entire costs involved so far are still under $15k but they will reach $20-$25k by the time its finished. I do get to sell off the old parts to help offset the costs . I did not put that into the equation yet. And I have a useless 1 5/8" complete B&B non turbo header/muffler setup (which was part of the $15k mentioned) to sell . The motor (S spec 2.2/webers) and type 911 5spd tranny shoud bring a few $ as well as the fuchs .

I hope im not going to get bashed by all you 930 guy`s. This is just my personal opinion. Its the help from you guy`s that I will need the most to guide me through this project.

Kurt Williams

>>OMG, Nogaro blue 911, how wierd. I was thinking about doing an RS replica after I got out of college in Nogaro blue.........well goddamnet, you beat me to it. <<

I was also thinking of a color just like that.
Rats!!

Hey 350hp ? Do you have a name ? I just checked the HKS link you just posted and funny thing is the guy sold me that same unit with the braided fuel line, fuel fitting for the fuel distributor, and a single injector which is meant to be mounted in the existing bung on the custom fabed intercooler he threw in with the deal . I dont plan to use it but may consider it if I dont find a EURO injection .

Kurt Williams

Yes, my name is Tony Rawson. :D

I didn't mean to sound like I was bashing, I was just wondering if the reason for your turbo project was due primarily to a attraction to the early models.

In my opinion nothing beats a turbo 911. If you have the HKS AIC it should keep you from having to worry about fine tuning the A/F curve on the car at above stock HP levels. The CIS is great but has a tendency to rise above the 12:1 A/F ratio that turbos favor at WOT conditions.

If I can get more than 400 HP at the back wheels when my project is complete I will be more than satisfied.

Tony I didnt say you were bashing. I was just asking not to be bashed for not finding a 930 to be more appealing than an early car. Reason being is that its just my opinion. Accually 10 years ago I liked the 930 look better. But my taste has changed and thats why I want to stay with the early chassis. We can all agree theres nothing lagging with the 930 cars as far as hp is concerned.

Kurt Williams

As i told you, ditch 930 arms (too much job fabricating new pickup-points unless you don't go full-race setup with new boxes with multiple holes for adjustable camber) and go for alu SC/Carrera arms. 930 and Carrera CV's have same diameter and SC/Carrera arms + 930 tranny + Carrera axles combo works in width department. At least that is what I believe, we just ordered Carrera axles so we'll be able to test this very soon...

Talking about extra stuff...you don't happend to have used 930 T/O bearing lying somewhere that i could buy?

We are making custom flywheel + 930 long tranny + 964 clutch + 930 early pressure plate combo and need to lenghten T/O bearing beacuse of adapter-plate between, so it feels unnecessery to buy new one just to measure it.

Cheers!

P.S. good engine-choice...now what about twin-plugging it and ditching CIS for EFI? Wayne had nice twin-plugged heads for sale...That would be a killer-setup :)

Wow! That is an awesome project! I like the look of the 930, but I also like the idea of a killer sleeper like this will be. Given today's craze for Carbon fibre and Fiberglass adornments, even with the 930 tail no one will suspect, until they are a distant memeory.....


Also, some enjoy driving, some enjoy collecting, some enjoy rebuilding/ modifying. These cars allow MANY people to enjoy them. I doubt I will ever fully appreciate the amount of work that goes into something like this, but I have bungled enough on my own to respect pjv's efforts.

Good luck. My hat is off to you. I will be looking forward to pics and a review of the first drive when all is done.

Heres a few rough pictures of the motor and parts I just bought on saturday. I was pleasently suprized to see that the 965 motor comes with a K27 stock instead of the K26 unit . The pictures of the parts boxes was the best I could do after spending a half hour unloading while the monday morning customers were sitting the the waiting room wondering why there cars were still outside not being worked on. I will get better pics soon. I will need a little help indentifing some of the parts at that time.
Oh yea the engine pics came out like crap and really dont show all the nice new detail the motor has. Allthough overall I think its an ugly motor as far as beauty goes(its no early motor with MFI thats for sure) . Well thats what a decklid is for anyway right .

Kurt Williams



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Ouch, get that air pump and the thirty pounds of plumbing off of there quick!!

There have been a few threads about fitting turbo motors and i-coolers in non tailed cars. Most seem to slope the ic back into the engine bay almost flush with the lid. Would seem worth a try in order to retain the classic look you like. Also, you could probably get away with a smaller ic as you are not after mega hp (perhaps one with a triangular cross section to fit into a duck tail???)

Here's one such thread:

http://forums.pelicanparts.com/porsche-911-technical-forum/117387-anyone-ever-intall-intercooler-out-tail.html

Cheers - Ryan

im looking to put a 930 turbo in my 68 rs replica and im desperate to have the rs ducktail and nothing else. im even thinking about fitting a pretty looking intercooler on the top of the engine and just removing any metal/fibreglass thats in the way. lets face it, a nice ally intercooler popping out of one of the nicest looking spoilers in the business would probably look great!

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Funny you should mention Audi's Nagarro blue with pearl effect. I went to the Audi Showroom while my car's body was being rebuilt and never considered another color to paint my car. I think this pic is squashed. Nice to see others appreciate the color as much as i do.

Patrick

Wow... Thats the first time I have seen someones post come out like that !!! What did you do ?

Damn! I was thinking of having my next car that color too!
There is a whole web site devoted to Nogaro Blue.
nogaro.org
-Chris

Yea that color rocks. It looks so much better in person. For some reason the camera cant show its true beauty.

Kurt Williams

Came back today from the spray booth. The paint laid on so nice that it doesnt need to be wet sanded. I will do it next spring when the paint is totally cured anyway just to get perfection.
The lighting plays such a role with the pearl in the paint that its hard to see the true color in a picture. But here it is anyway.

Kurt Williams

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The front and back are now assembled. Man this stuff takes patience.

Kurt Williams

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The C2 rear decklid which wont fit with the turbo motor ! OH WELL.

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Next project is the dreaded headliner install so I can get some glass in this thing. I hope wayne included this procedure in his 101 projects book.

Kurt Williams

kurt,
the car looks great! i know that the color is an audi blue but do you know if it is similar to the same blue the as the new 350Z? i ask because my bodyshop showed me a color that looked a lot like that blue.

also, how long to you estimate it took you to re-assemble? i ask because i expect my car back very soon from a full respray. they are re-installing the f/r windshield for me and that it.