I Swapped a 968 into a 924S

[JivenJim]

924S3.0
1987 Porsche 924S Epilog and Rebirth with 1994 968 Drive
AKA how to add 100+ N/A horse power 924S/944

For all those that were told that it’s not worth it to swap out Porsche Engines. It’s too expensive, too difficult, and you should really just forget it and buy something else. For those who would do, just because no-one thought you could or would. This Post is dedicated to you!

I’m working on a complete write up but here’s the Cliff note version.

8/18/05 Engine Dies at 204,051 miles Thursday 4:50 RIP my little German friend. Maybe you will find new live as a rebuild with someone less demanding for POWER!

So…Working on the Car in spare time after full time Electronic Engineering Job and foregoing TV and basically a life for three months.

10/27/05 “I've been throwing myself 110% at this dam car. Working late in the dark on weeknights and all weekends. Not sleeping, then dreaming of how to finish the next stage of the rebuild. I have read over 700 pages of spec's and procedures. Been on half a dozen chat rooms and tech forums. I am determined to win, cause every bolt seems to fight me. (can you say obsessive compulsive disorder) Quite a PITA”

So now Majority of work is done! It’s Running Great! Fast and Loud!

I still have projects on Dampening Vibrations and Sealing up the Spare Wheel well (cut out for extra Tranny room)

Major Upgrades
Complete 94’ 968 3.0L Vario Cam with MAF, Engine Swap with 26K miles!
968 6 Speed Tranny with LSD on custom mount
968 CV’s and Torque Tube
Spec Stage 2 Clutch
Bosh higher flow fuel pump
Lindsey Aluminum Flywheel
3” Custom Exhaust, High Flow Cat, and Flowmaster Muffler
8mm 1200F Braded Plug Wires
Blaster Coil
K&N Cone Air Filter
AC Delete Kit (Paragon)
Washer fluid system Deleted
Power steering Deleted (with Stock Rack)
250lbs Weltmiester springs, Blistein Struts and Shocks, Weltmiester Billets
968 External Oil Cooler
968 Aluminum Radiator and Duel Fans
Zimmerman Cross Drilled Rotors
Rebuilt Fuel System and Tank
Rebuilt Steal A-Arms with urethane bushings
Stainless Steal Brake lines
Ceramic Brakes on Stock Calipers 924S
New Sway Bar Urethane Bushings
Momo Steering Wheel
Natami Renegade Carbon Fiber Seats
Lindsey Ultimate Engine Mounts (may swap back to stock cause of vibration)
Home depot Carpet, Industrial grade, Charcoal, 9X14 ft
Kenwood 400 Watt Mosfet Stereo w/ Separate Powered Woofer

What it took:
-------------------------------------------------------------------------------------------
6 Cans of Industrial Strength De-greaser, 1 gallon Non-toxic cleaner
Approximately 220 Man hours direct labor (August 2005-December 2005)
Approximately 160 hours reading, Chatting rooms, and Supplies.
North of $14,000 in parts (car was a gift from original owner/mother)
Drank about 200 beers & 300 Dr. Pepper’s while on duty

Considering the Car was originally ~$35,000 the 968 was over $70,000
I’m OK with the cost.

Results:
==================================================
Estimated Power: 250 N/A HP
Estimated Weight: 2550 lbs
0-60 ~5.8 seconds
Plain Jane 924S Sleeper And NO LEAKS!

Future upgrades:
Replace or paint the interior Door panels and Redo Dash, Gauges and interior lighting.
Headlight Upgrade (Ice Shark)
Install a Keyless door/security system.
Fix the sunroof.
Bigger Tires
DME Chip

Special Thanks to those that answer the Questions so novices like myself could take on such a big task.


Golden Links

Manuals:
http://www.cannell.co.uk/Manuals.htm The PDF’s full 944/968/911 Manuals!. Very big files! And may take a few try’s to get em.
http://www.porsche.com/uk/accessoriesandservice/classic/classic-originalparts/originalparts-originalparts/ PDF’s of ALL Porsche parts PET diagrams, part numbers and exploded views of systems!
http://www.clarks-garage.com/ The ultimate how to source on how to.
http://www.geocities.com/eturbo924/Haynes.html Older 924 Haynes manuals

Swap References: examples
http://www.944s3.com/944S3/ 968 in a 944
http://home.earthlink.net/~bryangunn/main944page/id4.html S2 in a 924S
http://www.968turbo.com/clutch.htm reference for race clutch
http://spaces.msn.com/members/my968cs/ Race clutch info

Pros who I plugged for some Knowledge
http://www.andersonmotorworksinc.com/2005/contactus.htm San Diego Race Shop
http://www.speedforceracing.com/ East San Diego Custom Race Shop
http://comeauracing.com/about.htm Tim is 944 Spec PCA racing Guy


Parts:
http://www.lindseyracing.com/Merchant2/merchant.mvc?Screen=SFNT&Store_Code=LR These guys have great stuff and very helpful and friendly
http://www.gt-racing.com/ Body parts
http://www.broadfootracing.com/parts.htm couldn’t reach but cool site + AC Delete.
http://www.9xauto.com/944.html Very Cool parts, a must visit
http://fast44.com/engine.html Nice site
http://www.b-quiet.com/ultimate.html Well Worth the $200 and 20 LBS.
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&category=33701&item=7984508452&sspagename=WD1V for some Natami Seats. Very nice looks and
street to track for good price.
http://www.*****************.com/ Great web pages, parts. Shipping can take forever. Don’t talk to Chuck if he hasn’t had his coffee.
http://www2.9parts.com/parts good line of parts and pictures of them.
http://www.944online.com/cgi-local/ASI_Store.cgi?PPC+AW+porsche944+Entrance Looks cool.
http://members.rennlist.com/951_racerx/ Nice specs and info
http://www2.autopartsauthority.com/parts/autopartsauthority/parts.jsp?make=PO&year=1987&model=924-S-001 parts
http://www.autometer.com/cat_accessories.aspx?sid=51 Aftermarket Gauges

Head Lights upgrade:
http://www.gururacing.net/LightUpgrade.html

Exhaust:
http://www.americanmuffler-sd.com/index.html
American Muffler, San Diego, CA 858-277-0276 (Bret)
These guys are great prices for quality custom work. Very happy with their work.
Flow Master 40 series Muffler from Lindseyracing.com is Very, Very Loud. Sets off car alarms at 100 ft.

Suspension:
Bilstein Struts, and shocks w Weltmeister 250Lbs springs
Dave Turner Motorsports in Kearny Mesa, San Diego rebuilt the steal A-Arms, and Struts for me. (James) Good people to work with, but very limited stock on hand.

Ultimate semi-solid Engine mounts make the car Shake too much. Everything Rattles.. Everything! Would go Stock in hindsight.

Intake filter:
http://www.knfilters.com/search/univcone.aspx

Forums:
http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/ 924,944,968
http://65.61.16.109/forum/ 968 net
http://www.924board.org/ 924’s
http://forums.rennlist.com/ all
http://www.automotivehelper.com/cat394/ 924/944/968
http://www.porsche968uk.co.uk/phpbb/index.php 968’s
http://www.560sec.com/bulletinboard/index.php Porsche Hybrid Forum (Mostly V-8’s)

Articles:
http://www.9magazine.com/

Future Turbo Conversions?
http://www.powerhaus.com/
http://www.gururacing.net/

Junkyards:
www.autobahnparts.com Porsche/Audio Indoor, San Diego (ask for Sean for Porsche parts specialist) 619) 444-2290
http://www.20thstreetauto.com/porscheparts.htm#944
http://www.911pcar.com/Porsche_Parts/porsche_parts_lights.htm

[Moneyguy1]

That is truly cool!!

Kudos to you.

I always admire dedication and imagination.

[rammstein]

Wow. It took some guts to track the time and $ spent. I know that every day you walk out and see it, it will be worth it. Truly inspirational work.

[ae1969]

AWESOME...

I must agree ........ keeping track of all those things must of been quite a task.

Congratulations!

[Brando]

Amazing! I knew someone had to have done this conversion. Look, no brake master cylinder/booster clearance issues! Or were there?

I applaud you on a job well done! Go with 944 sport mounts, they won't transfer as much engine noise/vibration to the chassis as solid mounts and are pretty stiff.

Good job!

[pokey]

Nice. I'm jealous.

[JivenJim]

Thanks everyone for the nice Kudos! I take your compliments with great respect considering you are all connoisseurs of Auto engineering.

I actually keep a daily log for work performed. I wanted to try and remember what was difficult for lessons learned session and write up. Took lots of Digi-Pics on the way. I think I used just about every procedure in Clarks garage. The Online community has made this possible. I would of never tried this if I hadn't seen Matt on the 944S3 site I listed under references. I am a novice and learned most of everything on this first time adventure in patients.

Brando - I used adjustable height mounts, http://www.lindseyracing.com/Merchant2/merchant.mvc?Screen=PROD&Store_Code=LR&Product_Code=LR-944MM-UM&Category_Code=944ENGMOUNTS put them on the min, then added two steal washers between the Engine Crossmember and body. (about 3/4" lowered) I plan to remove those washers and replace with a rubber mat to dampen engine vibrations. I did bump the Brake Boost on install. I even Broke the Check valve and now can't unscrew to replace cause of closeness to intake manifold. So Now it's either gunky glue or remove the intake to fix. (reserve insertion needle broke) But all in all, that's not too bad. Where do you find those 944 sport mounts and are they adjustable?

The Back end was more difficult in coming up with a Tranny mount (old ear mounts on new 85.5+ centerline Tranny) Haven't driven it enough yet to say if my design is a winner. Good so far thoe.

[d.a.autry]

now THAT'S what I'm TALKIN' about!!!!

I've eyed the same conversion on my '83 944. Just don't have the $ yet.

All my p-friends say I'm crazy, and to sell the '83, take the money, put it with the money I'd spend on the conversion and get a NICE '88 or '89 turbo with the M030.

There's just something about the sleeper though!!!! Ain't nothin' like pullin' up alongside some of the snobs up here in Evergreen and dusting their S8, or C5, or Viper in a ragged out '83 944.

I've already upgraded some suspension components, and I run stickies with a pretty good camber. So it's pretty admirable in the twisties already. I'm sure I've left a few of the wondering on that alone. I just can't stand it though when they pull away from me in the straights.

ANYway, good job. . . and have FUN!!!

[rudidelange]

stunning!!!!1

[Paul Glasson]

You have my admiration. There has to be quite a motivation to tackle a project like that. My brother in law built a 34' steel hull yacht which took 12 years to complete, and I cannot comprehend the self discipline required to do what he did or you did. I stripped and rebuilt a 44, 10/12 Harley 26 years ago, and stripped to virtually last bolt and rebuilt an 80 SR500 Yamaha about 5 years ago. That is so easy in comparison to what you tackled. Adaptions become so tricky, time consuming and frustrating. I suppose if you really admire the lines of a vehicle or it is a real collectors item one can generate enough get up and go to do the job. I will watch and admire from a distance.
It must be cool to blow off some of the newer sports cars with your sheep in wolf's clothes. Err-I mean wolf in sheeps clothes.

[AA_Ezra]

Damm, *pause* That's *Pause* whoa.

[legion]

Very

[sasquatch]

One of our local Boise club members did the exact same thing. The car flys. King of the local auto-x track and flew at the hill climbs last year.

A worthwhile mod and a total "in your face" to the "buy a turbo" crowd.

[Rmills944]

What kind of carpet is that?

[josephsc]

Very cool! That's one fine looking engine bay. We'll have to a 968 swap get-to-gether at one point!

BTW -- so how much does the car weight now?

[procon]

[Timmay!]

Jim,
You wrote, "8/18/05 Engine Dies at 204,051 miles Thursday 4:50 RIP my little German friend. Maybe you will find new live as a rebuild with someone less demanding for POWER!

Your 924S engine HAS found new life as a 944 spec racing engine! It will probably go into my white 86 944 chassis. Either that or the red 86 chassis. In any case, it will be racing against other 944's in the 944 spec class soon. See you at the AX this Saturday. You have to be a club member and a registered entrant to AX your 924S3, though.

[JivenJim]

Wow Tim!

That would be a real showdown. My Old Engine in one of your 944 Spec Racing cars with you driving. Tim and his Mechanic John, Completely Rebuild the 2.5L N/A with the notorious spun #2 bearing and 5 bent values after my timing belt broke from a hose clamp, that somehow got in belt covered area. Don't ask me.?. I only had the car for a couple of months before that.

The Bummer part is Tim would still destroy me! (for now ;+) Tim is a top notch Racer/Instructor/Re-Builder/and the Local 944spec guy. (stock class 944 racing where the driver is the biggest factor) He runs rentals and lessons, so look him up if you need to rent or buy a 944 Racing Car, or sharpen your skills (in lovely San Diego. (so ends the gratuitous plug) Did I mention it's sunny and 65F today (as always)

Rmmills944- Carpet is standard roll industrial application Home depot. The Pre-formed was expensive and not as heavy duty and resilient as this at ~$40 Plus two cans of spray on adhesive. Took some work with the Scissors and it really not a show car job. But good enough for me and could be run all the way to the trunk in two pieces. (cut and back floorboard area floor major lap seam.

d.a.autry- I think rumbling with the big sport class is still outta the 4 cylinder class but, I hear ya man. It's respectable. This is a car of pose, balance, and agility. Besides my little 205's would probably just melt and fly off in a drag. However, In the turns, these cars will definitely hold there own.

josephsc- and anyone else that's made similar 924S/944 swaps: I would love a PM from ya so we can pool are knowledge and do a worthy site/write up for those that may dare to be foolish enough to be inspired by our examples.

Paul Glasson- OK here's the story of why. My mother was the original owner of this lovely little creature. I was 17 yrs and grew up drooling over it, washing it, and occasionally get to drive it. I even got to drive to my winter formal in this car. So you could say we have a history. I couldn't afford it then and couldn't afford a new one now. But, mom gave it to me to keep cause she knew I'd make it great again. My mother got her test ride 2 weeks ago and she couldn't believe it was the same car. (never mind that the car was completely gutted) She was proud. Quite a tear jerking moment.

I always liked how guys would rebuild old cars and make them look so fine. Older cars are more rare and special. And those of us who choose to embellish them are caretakers of our memories.
And like having a dog or a kid; cars teach us patients. Just don't keep the BFH close to your bruised knuckles.

[jgporsche]

Nice would be interesting on the track.

[Timmay!]

Jim, I'm thinking this would be a POC V3 class 911 stomper...........Heh, heh,heh.........