Converting lux to turbo

[Noahs944]

Hammerformed termination cap for the rear of the manifold.

[Noahs944]

Desperate times:

[Noahs944]

I'm just putting these down and walking away.

[Noahs944]

Stupid log manifold finally complete.

This has been... a good learning experience.

I can only hope that it doesn't break. If it holds together I will consider it a success (but only in the smallest victory). Next time, I will build the flange 1 piece and start fresh without using the old manifold.

Anyway, time to move onward. But first a few pics:

FTW.



I am proud of the fitment in the engine bay & around the oil filter. Installation onto head is a snap!



Next job is to shorten the height.

[Noahs944]

Shortened 120 degree elbow pipe by 3". test fit checks out okay. mig weld with both pieces while clamped tight to avoid warpage from heat.

[Noahs944]

Gotta grind the hanger for oil feed elbow.
Gotta grind the intake mount for exhaust flange.










Gotta figure out how to mount this.

[Noahs944]

This represents the approx position of the turbo inlet for the exhaust to drive the turbo and demonstrates the closeness to the intake (why I had to grind the mount off).



Among other things I plan for tomorrow is positioning & welding the external wastegate (which performs the task of exhausting the spent cylinder gases before they can spin up the turbo).
Installed one end of the turbo drain. I'm forced to tilt the turbo oil feed & drain at around 20 degrees to clear the driver side engine mount.

[Noahs944]

Ahh! It is RWD!

Mini Cooper with a Porsche 944 Motor – Engine Swap Depot

[v2rocket_aka944]

What was the reasoning not to mimic the 944 turbo exhaust crossover?

[Noahs944]

Easy as pie

[Noahs944]

[Noahs944]

Originally Posted by v2rocket_aka944

What was the reasoning not to mimic the 944 turbo exhaust crossover?

Hey brother, pleasure to see you here!

Answer:
Easier to work on, cleaner routing, less congestion. Would I go this route if the hood wasn't vented? No. It feels to me like a better design.

Part of my decision is based on the wastegate being vented to atmosphere vs back into the exhaust. I think I will try to vent into the pass side wheel well.

Part of my "oh... what the heck" attitude was based on the 944 GTR "official" Porsche approved 944 cars where there was no direct similarity to the road going version.

I've mentioned before that I don't like the 951 under the hood, I think the street cars look terrible to work on, so Wilson will always be designed to be very easy to work on.

That said, I might hate this! But in the mean time I think it gives the car uniqueness without having to jack the care up and crawl under to remove the turbo or exhaust manifold.

I hate my exhaust manifold. It *will* be replaced in the future, when I'm up for it I'll start fresh. Next time I will be able to tig weld.

Online research shows *around* 50-100 hp loss with my exhaust manifold compared to a 4 to 1. So my original goal of 350 rwhp is probably not going to happen. How much power does the 120 degree bend pipe steal? I don't know. Again, it's so far, my biggest regret but at this stage I just want to get Wilson back on the road and no doubt I will obtain this years goal of 220 hp even with the manifold and 120 degree pipe.

[v2rocket_aka944]

"log" vs tubular manifolds are an interesting subject...
tubular/equal length get the reputation of being better for max power which is usually true, but that doesn't mean a good log won't take you most of the way..

there are guys making 1000rwhp in 3.0 Supra's using a basic, cast-iron log manifold.

That said...
If you want to try something fancier, get on the road and go up the street a bit to your local Wolseley plumbing supply (parent company of my job @ Ferguson).
Ask for 1-1/2" carbon steel weld fittings...perfect size for 944 exhaust ports, cheap...

Calgary South Plumbing & HVAC/R
5516 - 3 St. S.E.
Calgary, AB, T2H 1J9

[Noahs944]

V2,
Holy crap!! That's pretty close to me.

Mind posting a picture to help me envision these "fittings"?

[v2rocket_aka944]

They are used for plumbing in applications where threaded connections are not needed or desired (steam?) or maybe just lack of space...



They are already used for turbo builds...
Zetec turbo manifold modification
http://www.nissanforums.com/forced-induction-nitrous-oxide/51055-instructions-make-your-own-turbo-manifold.html

[Noahs944]

AWWWW GEEZZZZE, those would be perfect!

Thanks for everything Muchacho.

[Noahs944]

Took some fiddling, but now have my manifold to turbo complete with 2 v-band clamps.

[Noahs944]

This is the turbo out flange that I welded the elbow to when I was going to run with the n/a intake. Need to cut the flange off for re-use.

[Noahs944]

This is where I am at right now. Notice the dipstick in relation to the turbo exhaust out. That's a tight fit. Now imagine fitting that, plus the exhaust from the headers (to spin the turbo-aka "turbo exhaust in") into the same space. Kinda fugly... hence my approach of front feed. Also front feed allows for more distance from fuel lines.



Now, some choices to make...

[Noahs944]

Okay I remembered I had the extra 120 bend elbow... and after a quick comparison, I decided 120 was the winner for performance and possibly even fitment. I cannot say enough good things about the quality of the "summit racing" pipe.



Recipe for a sweeeeet downpipe!