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Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
Posts: 955
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Stroker/Dry Sleeved 3.25T - Borg Warner EFR-7163

I had started another thread a while back about this build, but it was more related to planning, and went through a lot of different ideas and stages.
Things are finally coming together in one state (literally, things are getting here to Oregon now... ha)

The car is an 88 Turbo S Silver Rose (or was). Now has Broadfoot flares, runs 295 Hoosier A7 in front on 18x10 MY02 wheels and 315 in the rear on 18x12 MY02 wheels (widened from 8").
The ECU I run with is what I bought the car with - Wolf3d V400, which is versatile, but old. Hard to find a tuner excited to work with it, but PRE Racing here in Portland will work on it for me.
I run the car at hillclimbs and autocross, and building primarily for corner exit up hills.

Where I am at:
- 94mm offset grind crank
- Dry sleeved 105mm bored S2 block, balance shafts deleted
- A/C deleted
- Borg Warner EFR-7163, V-band in and out, internally recirculated, not internally wastegated
- Custom JE Pistons
- Mitsu 4g63 bearings
- Eagle 4g63 rods
- Head work done by Michael Mount:
-- Int Valve: 48mm
-- Exh Valve: 40mm
-- Springs: 130# on seat (Porsche outer, MM inner)
-- OK for cam up to .515 lift
-- Combustion chamber: 62.7cc
-- Surface cut .004
-- Competition valve job
-- Intake and exhaust ports shaped and optimized.

I have all the main parts now, I just have to get them to the machine shop for boring and short block assembly now.

Good times ahead!









__________________
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; 03-15-2018 at 08:34 AM..
Old 03-15-2018, 08:30 AM
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Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
Posts: 955
Garage
Dropped off the block, crank, pistons, rods, bearings, and head at M and B Cylinder Heads this morning. Found I don't have the 6 and 8mm hardware for the crank girdle, which is pretty essential to make sure things line up and clearances are good... I haven't gotten my old motor all the way out yet so im going to have to source some hardware to get to him asap.
Should be a few weeks until hes done with the boring, decking, gapping, clearancing, and shortblock setup. gonna order the turbo later this week, then continue disassembling the old motor to get ready
__________________
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 03-21-2018, 11:47 AM
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Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
Posts: 955
Garage
This build is going a bit slow -
I have the short block assembled now.
I have a modified oil pickup tube.
Converted to manual flip up headlights.
Ordered a catch-can setup.
Have my new power steering lines.
Got my quick release and Momo wheel installed.
Havent put the new seats in 100% yet, nor harnesses.
Weld in cage from 944cage.com is on its way - they made adjustments because my classing requires me to keep basically full interior. I've taken out most of what I can take out - rear seats, stereo, spare, headlight mechanisms, replaced front seats, AC delete, washer reservoir deleted... Not a lot I can do. Then I put in the cage and it will be back right where I started!
Ill also be using an 044 Bosch pump, and upping my injectors in size again.

I'm also in the middle of building a garage next to my tiny attached garage - not to mention every weekend im out of town at events. Hoping that if I get this motor mostly assembled that will get my butt in gear to get the rest done. Ive pretty much come to grips with the fact that I wont likely be driving it this year at any events...

Im looking into aero as well - Nine Lives Racing has a proven wing - and I have a local shop that will help me fab up some mounts for it that meet class requirements.
I'll likely go with the wood splitter in the front, as I'm guessing I will go through them more often than preferred... The hills occasionally have bumps and things - as well as some of our AX sites. And getting it on the trailer will be fun... Have to rig up some serious ramp extensions.

But, its coming along bit by bit!
__________________
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 07-19-2018, 11:47 AM
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In the Fires of Hell.....
 
kdjones2000's Avatar
 
Join Date: Oct 2007
Location: Phoenix, AZ
Posts: 3,041
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Looking good (and expensive!)
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NASA/PCA Instructor: '88 951S - with LBE, Guru chips, 3Bar FPR, 1.3mm shimmed WG, 3120 lbs, 256 RWHP, 15 psig boost
1987 924S 944 SPEC racecar - '88 pistons/DME, short 5th
1987 944S - Restored salvage title, ready to live again
I can fix your late 944 Cruise Control module - PM for details
Old 07-19-2018, 12:17 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #4 (permalink)
Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
Posts: 955
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Quote:
Originally Posted by kdjones2000 View Post
Looking good (and expensive!)
this has been insane for what I normally do.
But once the car is down and apart, it becomes just another few hundred... and another few hundred... might as well do this while im apart....
__________________
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 07-19-2018, 01:33 PM
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Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
Posts: 955
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started assembly. realized I had the wrong head studs, ordered up some from ARP, and now I think I have everything except time!
if I can take a day, I can probably get the motor mostly together
__________________
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 08-16-2018, 10:41 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #6 (permalink)
 
Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
Posts: 955
Garage
Got my ARP studs that are the correct length for a 3L with 8v head (not marketed for the 944).

Welded up the balance shaft drains, had to cut the lower cover to keep the ability to mount the PS pump.

I've gotten the front of the motor together, timing belt in place, but I forgot to order an idler roller and pulley for the tensioner, so waiting on those.

Ordered a new 4an line for the oil feed which is tapped directly to the block where the feed would have been for the balance shaft bearing.

Got the turbo on for mockup, all looks good.

Also got my new semi solid mounts in the mail and picked up my parts dash to fill the cracks and flock with burgundy flocking.

Not sure if I mentioned I ordered a wizard radiator.

I DESPERATELY need to remember to tap for the "steam vent", which I keep forgetting to do.

Here's a pic before I got it all together:



__________________
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 09-05-2018, 11:17 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #7 (permalink)
Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
Posts: 955
Garage
Motor is in. Just working on getting it all connected up
I went ahead and got a JME 8SR-14 cam, spherical castor blocks, and RSBarn Harmonic Balancer.

Working on making phenolic intake manifold spacers. almost done. porting the intake manifold and making these spacers pretty much all by hand with a drill and file. dremel is useless and gums up. between the intake mani and the spacers the shape goes from the 2.5 intake manifold shape to the D port shape on the 2.7 head.

Things are going a little slow, but im putting more time in now that its this far. The other day for example, i bumbled around all day. First i was going to put the clutch in, but i found i forgot to order pressure plate bolts. then i was going to disassemble my wastegate to put together the new one, but i couldnt find ANY of my 6mm allens. Then i was going to do my suspension, but i found out when i bought the camber plates they sent me the wrong ones. was going to regrease my castor blocks, but found i dont have snap ring pliers to get them apart.
sensing a pattern here!?

i did get the power steering on last night. partway through i realized i made the biggest 944 mistake there is. i didnt install the thermostat with the engine out. LOL. okay its not that bad but seriously.. so much easier out.

__________________
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 01-21-2019, 03:34 PM
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Registered User
 
Join Date: Jul 2014
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Garage
Looks like an awesome build! Those pistons look deeply dished. Is this a non-interference design? Looking forward to seeing more updates and impressions of what this beast is like to drive.
Old 01-28-2019, 04:53 AM
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Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
Posts: 955
Garage
Quote:
Originally Posted by 1blk968 View Post
Looks like an awesome build! Those pistons look deeply dished. Is this a non-interference design? Looking forward to seeing more updates and impressions of what this beast is like to drive.
Unfortunately its still interference. CR should come in right around 8.25:1
And I'm definitely looking forward to impressions of what it feels like to drive too!

I got the clutch in yesterday, and the intercooler and oil coolers. Have a bit of a snafu with power steering. Nothing changed, now the belt is suddenly too long... I will look into it more later to see what happened. I may have simply grabbed the wrong belt, but I dont think I had any other belts, and I cant find any others in my stuff...
__________________
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; 01-28-2019 at 10:19 AM..
Old 01-28-2019, 08:41 AM
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Registered User
 
Join Date: Feb 2007
Location: Phoenix
Posts: 314
It looks awesome...


Except the cam tower. SMH.
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1971 914 First Car (SOLD)
1972 914 rust bucket (SOLD)
1986 944 Turbo (Murdered by a Chevy Truck on the freeway)
1990 944 S2 Cabriolet - Long term project
1971 914 - Long term project #2
Old 02-06-2019, 03:55 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #11 (permalink)
Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
Posts: 955
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Quote:
Originally Posted by azbanks View Post
It looks awesome...


Except the cam tower. SMH.
damnit! lol. im about to get some nail polish and touch it up so it looks better in pictures
racers cant be choosers
__________________
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 02-07-2019, 10:28 AM
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Registered User
 
Join Date: Feb 2007
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Posts: 314
Nail Polish???? Funny, that doesn't look like a Boxster.
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1971 914 First Car (SOLD)
1972 914 rust bucket (SOLD)
1986 944 Turbo (Murdered by a Chevy Truck on the freeway)
1990 944 S2 Cabriolet - Long term project
1971 914 - Long term project #2
Old 02-07-2019, 05:35 PM
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Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
Posts: 955
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Lolol.
If I knew the paint that was used I'd just touch up that one big spot, but I don't :/
__________________
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 02-08-2019, 10:22 AM
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Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
Posts: 955
Garage
torque tube is in, trans going in in the next few days. its getting closer! interior is still torn apart. i need to finish flocking the dash and get it back together.
then ill be taking it to a friend to weld on the exhaust a bit before final assembly and ready for a tune.
oh and i have to swap fuel pumps to the 044. i dont remember how much gas i have in the tank, but i think i know =/
__________________
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 03-14-2019, 02:43 PM
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Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
Posts: 955
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bosch 044 pump is now in. i planned on putting the trans in, but ended up helping my girlfriend with spanish homework most of the day (she has some health problems and ended up falling pretty far behind).
By most of the day, i mean she worked with almost no break from 10am to almost 3am... I helped from about 3 or 4pm until 2am.

Did i mention above that i didnt know how much fuel i had in the tank? its a good amount, and still is. I think i managed to only lose about a cup, but it was a stressful time managing to minimize the amount. I swapped out the line that attaches to the tank even - pulled the line and stuck my finger over it as fast as i could. then moved my finger and stuck the new line on as fast as i could. i think i actually lost less there than any other step of the way.
had to cut the cover plate some because the elbow stuck out so far, but overall it was a pretty easy swap.
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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 03-18-2019, 09:23 AM
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944 addict
 
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I just had to do the same thing. Didn't lose much fuel and had the elbow line between the pump and the fuel tank crimped with small vise grips so it wouldn't keep pouring until the whole thing was reassembled.
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3 944's, 2 Boxsters and one Caman S, and now one 951 turbo. Really miss the Cayman.

Some people try to turn back their "odometers." Not me. I want people to know 'why' I look this way. I've traveled a long way and some of the roads weren't paved.
Old 03-18-2019, 03:48 PM
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Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
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Yep that's what I did as well, until that one had to be replaced, then it's go go go!
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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 03-18-2019, 03:51 PM
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Are you not worried about the secondary harmonics in this engine with stroker bits? Is crank very light?
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'83 944 ROW zermatt silver/black, sunroof & A/C factory deleted, houndstooth sport seats, 7Q - 220 LSD short fifth, F & R 23.3 MM 951 M030 suspension, 16" fuch's, manual windows, club sport mirrors, Blk/Wht gauges, rear seats & all sound deadening removed, 968 rear wing, fiberglass hood & 937 F bumper
Old 03-31-2019, 01:31 AM
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Autocross/Hillclimbs
 
Join Date: Oct 2012
Location: Wilsonville OR
Posts: 955
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From what I've read, keeping the idle high will mask most of the vibration. Additionally I went with the rsbarn harmonic balancer. Many have run with no balance shafts. I am curious to see what it will end up like though.
__________________
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 03-31-2019, 05:22 AM
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