Part VIII Megasquirt 944 Turbo - Go big or Go Home

[ae1969]

Part VII - Previous update

Well the snow has fallen and Christmas has just passed and the new year is upon us.

So we continue with our project.

I managed to hit the dyno during the early summer of 06' and hit a 315rwhp and 320lbft at 16 psi........ Our goal was to clear 300 with a conservative tune and that we did.
We will be pushing for 350rwhp the next time we are out but first we need to clear up the outstanding issues that came to light at our dyno session.

The only issues that surfaced at our dyno session were knock sensor issues (aftermarket setup), a slight missfire at high rpm and a IAT that would heat soak like you would not believe.

The knock sensor issue was cleared up by actually wiring it correctly! The knock sensor is now working perfectly without issues.

The slight missfire was corrected by using plugs with resistors and a smaller gap on the plugs.

The only thing that remained was the heat soaking IAT.

The car ran the remaining 2-3 months without a hiccup. ........ and was running stronger than ever before I had to park it.

The project for this winter is to increase the intercooler size and relocate the IAT that is currently 5-6 inches away from the throttle body to a location closer to the new intercooler.

The stock intercooler in the 944 turbo is actually a relatively efficient setup. The stock core size is 5 x 5 x 18. There really is no need to change the intercooler on a stock car but on my car I have already opened up the intake and exhaust side. The intercooler is one of the restrictions that currently remains as we push for bigger numbers.

IMO there are only two possibilities for upgrading the stock intercooler.
1. A setup similar to that is supplied by Speed force racing that drops the intercooler below the structural brace that spans accross the 2 front rails.
2. You cut the structural brace.

I opted for 2. I have other plans that make option 2 viable. Once you go this way there is no turning back.

THe project begins by removing the turbo bumper assembly. Relatively easy procedure when you have done it more times than you can remember.

Step 1. How it looks before.


Step 2. Cutting is so easy this way.....


Step 3. The space that is now available.


Intercooler opening now is approximately 24"(width) x 20"(height). The core depth that can be used easily accomodates a 5+ inch core.

Now we have many more options.

There are issues in regards to pressure drop versus lag vs efficiency etc....

IMO I want my temps down. I have logged what the stock intercooler achieved in my current setup and I was not impressed. There is room for improvement.

I hope to have a new intercooler setup within a couple of weeks.

Once the new intercooler finds a home we will then tackle air flow. The 944 turbo has got to be one of the hottest running engines ever produced. It is truly insane.

The solution I am implementing is simple. The hood will meet the plasma cutter.

New ducts, vents and air intake locations are up for grabs. The plasma cutter will be busy.

[AznDrgn]

NICE!!! I need to get my ass in gear and finish building my MS unit.

[speedracing944]

me as well.

Good work!

Speedy

[JustinL]

Wow, nice amount of space freed up there. Are you going to keep the a/c? or dump that too? We could make some ducting to vent all the hot air from that mess of rad, a/c, intercooler up out the hood if you decide to slice that open too.

I'm back from Maui if you want help doing whatever.

[ae1969]

Originally posted by JustinL
Wow, nice amount of space freed up there. Are you going to keep the a/c? or dump that too? We could make some ducting to vent all the hot air from that mess of rad, a/c, intercooler up out the hood if you decide to slice that open too.

I'm back from Maui if you want help doing whatever.

I am actually surprised how much room there is.....

I want to keep the A/C

I am sourcing out different intercooler options......... definitely need to come up with some creative duct work....
I would like to reposition the intake as well....... a big hood scoop maybe.

[CJFusco]

ae, you're my hero.

[ae1969]

Well ......

The intercooler came in.... looks like a perfect fit.

Need to finish welding some mounting tabs and she will be good to go. (Note: Intercooler needs to be placed 1-2 inches higher than what is depicted in the picture)

The core is 18"x12"x3.5". The use of a 5" inch core would of meant loosing A/C. I like my A/C so a 3.5 inch would have to do. The surface area has approximately doubled with this core size.........

The end tanks also add approximately 6 inches to the unit. The width is 24" that fits comfortably in between the headlight buckets.........

[JustinL]

LOL that's HUGE!!! Are the inlet and outlet on the back of the tank or do you have to weld those on too? Now the only thing left to figure out is where to put that IAT sensor bung.

[ae1969]

Originally posted by JustinL
LOL that's HUGE!!! Are the inlet and outlet on the back of the tank or do you have to weld those on too? Now the only thing left to figure out is where to put that IAT sensor bung.

I did mention BIG.

LOL.

The inlete/outlets are on the back.

THe IAT has me thinking...

[speedracing944]

i zoomed in on your photo and I saw Peterbilt stamped on the side of your intercooler.

Speedy

[Eldorado]

hot.... damn....

[JustinL]

OK buddy, quit keeping me in suspense here! Let's see the finished product

[ae1969]

A couple of pics taken while visiting Justin ...... You can just see that bad boy peaking through the bumper.........

[ae1969]

[CJFusco]

My 951 is to your Megasquirt 951 as I am to Steve McQueen.

Very, very well done.

Might be a silly question... but how does she run?

[ae1969]

Originally posted by CJFusco
My 951 is to your Megasquirt 951 as I am to Steve McQueen.

Very, very well done.

Might be a silly question... but how does she run?

hehehehe

She runs better than she ever did on bosch motronic.

My biggest problem is traction. SHe is pulling very hard. I have the boost set to 18 psi with occasional blips at 20.

Next on the list are some wider wheels. The 255's are getting eaten up.

[CJFusco]

I can imagine traction is an issue... mine can easily break traction around most turns with a stab at the throttle, and mine is practically stock. I can't imagine what 20psi would be like...

[ae1969]

http://www.youtube.com/watch?v=eLH1aI3Wo4A

Building boost at a stand still......

[ilikemy944]

When putting the turbo setup and nose on the n/a chassis did you have to do anything as far as mounts go?
I may end up swapping my 951 to another chassis, and it is much easier to find an n/a that isn't wrecked cheap.

Why? you ask... because my non-wrecked 62k mile 951 has an interesting pair of frame rails forward the engine mounts.

[ae1969]

Originally posted by ilikemy944
When putting the turbo setup and nose on the n/a chassis did you have to do anything as far as mounts go?
I may end up swapping my 951 to another chassis, and it is much easier to find an n/a that isn't wrecked cheap.

Why? you ask... because my non-wrecked 62k mile 951 has an interesting pair of frame rails forward the engine mounts.

Hey Uni-nut.

I had the benefit of having an 86NA and 86 Turbo so it was a straight swap. No issues.

Surprisingly pretty straight forward.