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Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
Posts: 840
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1988 Porsche 944 Turbo S (Silver Rose)

Wolf3D V400 EMS using MAP sensor
J&S Knocksafe (tuned for 18psi on premium fuel, tunable via laptop)
B&B Header
EFR 6258 Turbo with internal recirc valve
3" Stainless downpipe (ceramic coated)
4" Lindsey Racing stainless cat-back
custom oil cooler w/new lines
Custom aluminum intake piping (larger diameter)
Aluminum flywheel
Spec Stage II clutch
Tial Wastegate
55# injectors
Aluminum fuel rail
Adjustable Lindsey "stock location" FPR
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2x 1984 944 N/A; 1988 951S Silver Rose; 81 VW Rabbit Diesel; MK4 VW R32
President - Bridge City Autosports
http://www.bcautosports.club

Last edited by PDX-944; 01-12-2016 at 01:29 PM..
Old 01-12-2016, 01:27 PM
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Yeah, I would definitely look at larger injs. Especially if you try E85 at some stage.
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Old 01-13-2016, 02:44 PM
  Pelican Parts Technical Article Directory    Reply With Quote #22 (permalink)
Autocross/Hillclimbs
 
Join Date: Oct 2012
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I will not be running e85. im not that into it. lol. too much work =p
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2x 1984 944 N/A; 1988 951S Silver Rose; 81 VW Rabbit Diesel; MK4 VW R32
President - Bridge City Autosports
http://www.bcautosports.club
Old 01-13-2016, 03:40 PM
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I've been running it for about 6 years. Had very few issues and many benefits from it.
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Youtube 333pg333

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Old 01-13-2016, 05:48 PM
  Pelican Parts Technical Article Directory    Reply With Quote #24 (permalink)
Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
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There was originally a remote to switch tunes on the fly for the v400. It broke a few owners ago. I can't seem to locate another. That would be nice. .
__________________
2x 1984 944 N/A; 1988 951S Silver Rose; 81 VW Rabbit Diesel; MK4 VW R32
President - Bridge City Autosports
http://www.bcautosports.club
Old 01-13-2016, 08:00 PM
  Pelican Parts Technical Article Directory    Reply With Quote #25 (permalink)
Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
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Got the gauges installed today. Theyre not perfect, but i think its pretty good. I need to paint the pods with something. Theyre just good old schedule 40. Havent finished the wiring yet, so still have the stereo and stuff out.
Received the oil drain flange/mount adapter. Also swapped over the oil and water lines.
Nice thing about modding a modded car- all the fittings are the same, so the oil and water lines all went on like cake.
Also a comparison old turbo compressor wheel to new (much smaller). 72mm wheel was just a handful of hair too much.















__________________
2x 1984 944 N/A; 1988 951S Silver Rose; 81 VW Rabbit Diesel; MK4 VW R32
President - Bridge City Autosports
http://www.bcautosports.club
Old 01-17-2016, 07:13 PM
  Pelican Parts Technical Article Directory    Reply With Quote #26 (permalink)
 
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Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
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So Fab9Tuning...
I emailed them on January 6th about a broken nipple on the boost control solenoid. They quickly replied that they would send a replacement. Tuesday the 12th I talked with them and told them that I realized they also forgot to send the V band flange I ordered and paid for with the turbo, and wanted to add another v band flange as well. They said sure thing. Here I am January 21st still haven't received that stuff, and have had no confirmation emails or contact from them. Ive called and left messages the last 2 days, no replies.
Getting a bit peeved.
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2x 1984 944 N/A; 1988 951S Silver Rose; 81 VW Rabbit Diesel; MK4 VW R32
President - Bridge City Autosports
http://www.bcautosports.club
Old 01-21-2016, 02:23 PM
  Pelican Parts Technical Article Directory    Reply With Quote #27 (permalink)
Autocross/Hillclimbs
 
Join Date: Oct 2012
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Left a third message today, saying that I would wait until next week and if I hadnt seen or heard anything, i would file a claim with the credit card company, and then resubmit a payment for the amount of the turbo minus the broken piece and pieces that werent sent. Literally 45 seconds later I got a return call. So why didn't he call without a threat?
He said the parts are coming directly from Borg Warner, and that he would call them and call me back. I'm still waiting for that call back
__________________
2x 1984 944 N/A; 1988 951S Silver Rose; 81 VW Rabbit Diesel; MK4 VW R32
President - Bridge City Autosports
http://www.bcautosports.club
Old 01-22-2016, 11:07 AM
  Pelican Parts Technical Article Directory    Reply With Quote #28 (permalink)
Autocross/Hillclimbs
 
Join Date: Oct 2012
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apparently borg warner did not have a replacement boost control solenoid, so borg warner didn't send anything.
he told them to send the flanges I ordered and he took a solenoid off another new turbo and is sending that...
ugh.
so when I actually get ahold of Fab9, the service isn't bad, but its the communication that sucks.
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2x 1984 944 N/A; 1988 951S Silver Rose; 81 VW Rabbit Diesel; MK4 VW R32
President - Bridge City Autosports
http://www.bcautosports.club
Old 01-22-2016, 04:08 PM
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Communication is the bane of most people's customer experience as a shopper nowdays. Good to hear you maybe getting some progress shortly.
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Old 01-23-2016, 08:16 PM
  Pelican Parts Technical Article Directory    Reply With Quote #30 (permalink)
Autocross/Hillclimbs
 
Join Date: Oct 2012
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Got the turbo ready to mount with the adapter. But the bolts are now not long enough. I think I'll end up using allthread as a stud with a nut at the bottom instead.
Old 01-23-2016, 09:09 PM
  Pelican Parts Technical Article Directory    Reply With Quote #31 (permalink)
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So what injector options do I have?
I'm running an aftermarket ems so I'm not as limited as from the factory.
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2x 1984 944 N/A; 1988 951S Silver Rose; 81 VW Rabbit Diesel; MK4 VW R32
President - Bridge City Autosports
http://www.bcautosports.club
Old 01-26-2016, 10:42 AM
  Pelican Parts Technical Article Directory    Reply With Quote #32 (permalink)
Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
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alright, so I went ahead and got 72# siemens injectors, part 3145
should be in next week.
hopefully those flanges from BW will come in today or tomorrow. goal is to get that part going this weekend and get the longer mounting hardware taken care of too
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2x 1984 944 N/A; 1988 951S Silver Rose; 81 VW Rabbit Diesel; MK4 VW R32
President - Bridge City Autosports
http://www.bcautosports.club
Old 01-27-2016, 01:03 PM
  Pelican Parts Technical Article Directory    Reply With Quote #33 (permalink)
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#72's are an advancement. You can always upgrade to larger if they reach too high a duty cycle.
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Youtube 333pg333

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Old 01-28-2016, 01:56 PM
  Pelican Parts Technical Article Directory    Reply With Quote #34 (permalink)
Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
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Think I should have gone even bigger?

Got the replacement solenoid and outlet flange.
I told him to add an inlet flange and he didn't. I won't be dealing with Fab9 again. Ill pay a bit more and order from full-race this time.
__________________
2x 1984 944 N/A; 1988 951S Silver Rose; 81 VW Rabbit Diesel; MK4 VW R32
President - Bridge City Autosports
http://www.bcautosports.club

Last edited by PDX-944; 01-29-2016 at 01:26 AM..
Old 01-29-2016, 12:43 AM
  Pelican Parts Technical Article Directory    Reply With Quote #35 (permalink)
Autocross/Hillclimbs
 
Join Date: Oct 2012
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With the oil drain adapter im using, only the longer oil mount bolt needs to be replaced. The shorter one threads into the adapter, the longer one passes through it and into the turbo.

For anyone running into this, the bolt I ordered is M8X1.25X140mm, from belmetric.com
This should be the right length, if anything I may need to shave a few mm off.

Cut the old downpipe flange off, and along with it removed a good inch of material which should be a better fit. Previously exhaust was rattling on the castor block mount.
So we tack welded the new flange on, but until I get the inlet flange and we mock up the crossover, we won't complete the welding yet.

The oil line is a bit short. The hard line off of the block is tipped up at an angle, and if I could bend it just slightly it would line up perfectly, but it seems very difficult to bend so I'm not sure what I'm going to do at this point.
Water lines are perfect. Pretty much all the adapters and everything from the old turbo fit perfectly on this turbo, which is nice. I even test fitted the intake manifold, and have plenty of room.

The previous charge pipe to the intercooler fits perfect. I still haven't figured out how I'm going to plug the hole for the previous blow off valve on the aluminum pipe going from the intercooler to the intake manifold.

With the Wolf3d v400 ecu, I could have ditched the narrowband o2 and connected an LSM11 wideband to it, but I didn't know this, so the wideband kit I had ordered has an LSU4.2 sensor, which is not compatible. Unfortunate, but oh well...
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2x 1984 944 N/A; 1988 951S Silver Rose; 81 VW Rabbit Diesel; MK4 VW R32
President - Bridge City Autosports
http://www.bcautosports.club

Last edited by PDX-944; 02-01-2016 at 08:14 AM..
Old 02-01-2016, 08:09 AM
  Pelican Parts Technical Article Directory    Reply With Quote #36 (permalink)
Autocross/Hillclimbs
 
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alright, the inlet flange finally got here from Full-Race, now just waiting on the long turbo mount bolt. that should be the last essential piece to the puzzle.
then I can really get things welded up and mounted and start putting it together. then its off to the tuner.
woot! im excited to get this going. only a month until autocross starts.
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2x 1984 944 N/A; 1988 951S Silver Rose; 81 VW Rabbit Diesel; MK4 VW R32
President - Bridge City Autosports
http://www.bcautosports.club
Old 02-05-2016, 09:25 AM
  Pelican Parts Technical Article Directory    Reply With Quote #37 (permalink)
Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
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things are ready to go back together! getting the vbands on the exhaust all lined up was a PAIN. theres one at the inlet, one at the downpipe meeting the turbo, another on the downpipe just before the castor block, and another just after the WG dump tube.
that was ridiculously not fun, but it all came together finally.
so the reassembly and tune process will begin! hoping to get most done this weekend
__________________
2x 1984 944 N/A; 1988 951S Silver Rose; 81 VW Rabbit Diesel; MK4 VW R32
President - Bridge City Autosports
http://www.bcautosports.club
Old 02-19-2016, 03:07 PM
  Pelican Parts Technical Article Directory    Reply With Quote #38 (permalink)
Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
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I know soooo many people are following this... haha

sunday I got the car 90 percent together. Just have to reconnect the steering rack, get the heat shield around it, button up a few exhaust bolts, and finish tying up some wires.
I also need a reducer coupler for the intake pipe. I forgot to measure it, but I can at least fire it up without the pipe on there (map sensor).

two concerns -
first, BW recommends filling the center section with oil prior to connecting the lines and firing up. that's impossible on our cars really. I put some heavier oil in, as much as I could (not much at all), and I will disconnect the coil wire so I can both check fuel pressure, oil pressure, and allow the turbo to get some oil flow. then ill let it idle when I DO fire it up the first time.

second. its been sitting all winter with premium fuel in it. should I just top it off with more premium before getting it tuned? will it matter too much? im not sure how much is in the tank at this point, hopefully not much

Heres where I'm at. Im reading mixed reviews about leaving the FP Gauge underhood. hmm.
you can see the quest alternator in place. It was definitely not straightforward. LOTS of grinding on both the alternator and the mount. I also found that the 951 and 951S alternator mounts are different ever so slightly. but both fit. the 951S bracket is slightly thinner for most space. I found that out AFTER I modified the 951 bracket to fit, of course. so I just went with it.

__________________
2x 1984 944 N/A; 1988 951S Silver Rose; 81 VW Rabbit Diesel; MK4 VW R32
President - Bridge City Autosports
http://www.bcautosports.club

Last edited by PDX-944; 02-23-2016 at 12:23 PM..
Old 02-23-2016, 09:47 AM
  Pelican Parts Technical Article Directory    Reply With Quote #39 (permalink)
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Congrats on your progress. Did you get any/many pics of the turbo in position before the inlet and other parts were installed? Is that the stock Alternator? Would like to see how tight it is in there with the turbo etc.
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Old 02-25-2016, 07:33 PM
  Pelican Parts Technical Article Directory    Reply With Quote #40 (permalink)
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