3.2 Turbo Build

[Black_Hat]

Here are some pictures of a RUF 964 N/A conversion to Turbo. I leeched these off the internet some time ago.
Hopefully you can get some insight on hoe RUF did this.

[Black_Hat]

[quattrorunner]

Wow that was a nice kit.

[Coultl]

Oh man, so cool. Thank you for sending! Looking closely at the turbo location…

[decisive1]

That is some pretty tight packaging.

[Coultl]

I made a little progress and started work on the intake. A few notes on the photos below:

I routed the turbo intake into the engine bay and up to the location of the relays/fuses. This panel will be removed since I am running a standalone ECU and not heater fan or defroster. It ‘seems’ like the ITG filter will fit nicely here. The plan is to design an enclosure for the filter. I think it could look pretty nice.

The exhaust side turbine intake pipe and turbo placement has been improved. The new wastegate location is much better.

The one challenge I have is that the turbo drain is barely above the bottom edge of the cam cover. I’d really like to just gravity drain into the cam cover and not deal with a scavenging pump. I designed a hyper low profile turbo drain fitting that could be 3D printed in stainless steel. Every mm counts so it needs to be this extreme.

I realize that I’m breaking nearly all of the turbo drain ‘rules’ but I think it may work, mostly because the ball bearing turbo is fed through a 1mm orifice. The oil flow is very low.

[Coultl]

Some prototyping

[moparrob]

Wow, great skills there. Are you SLA printing your prototype pieces? If so, what is your setup?

[quattrorunner]

Ya that's cool

[Coultl]

Thanks! These are FDM prints made out of PLA plastic. I use a Bambu printer. They are really solid. I print a lot when thinking something through. It’s cheap and helps me iterate and improve.

[moparrob]

Looks good for FDM with PLA.

[Ooffenhausen]

Love the hotside pipe so far, the waste gate placement looks about as good as you can get it. Looking forward to seeing this play out. Always cool to see how technology trickles down to dudes doing fun stuff in the garage.

[Coultl]

Currently tearing down the engine (in another thread) and making progress on the CAD. I did design the Y-Pipe which I'll also 3D print in 316 stainless. Not much progress overall, but I did come to a conclusion on the placement of a few things.

I had planned for the turbo charge pipe to go straight up into the engine bay through a cutout in the tin. After I dropped in a more detailed engine scan I realized that the coil on plug for cylinder #2 is right in the way. I could probably make it work with a bunch of compromise but....

That got me thinking. Maybe I can keep the engine bay very clean looking and avoid heat soaking the water to air intercooler by routing the charge pipe in the wheel well. Felt like sacrilege at first but then I realized this is where all modern turbos put their charge piping and intercoolers.

Hard to explain without photos, and I'll share once the cad is a little more developed. Basically the charge pipe will go up from the turbo and then forward along the top edge of the wheel well. The intercooler will be located in the front section of the wheel well. The charge pipe exiting the intercooler will then enter the engine bay through the wheel well. No intercooler and the charge pipe entering at the back of the engine bay will leave the engine bay very clean and uncluttered.

Hard to explain but I think it's a really nice solution. Also, the water cooler for the air to water intercooler will be located in the same spot as the front factory oil cooler but on the passenger side. I'll just need to figure out a new spot for the windshield washer tank and such. Other have mounted oil coolers here so I know I can make space for it!

[Coultl]

Some CAD images. Will figure out the charge piping next.

[Coultl]

[greglepore]

That intercooler location will work, just have to protect it from stones etc.
Protomotive turns the air filter the opposite way, it ends up under the driver's side parcel shelf. Suspect its a toss up as to which location makes service easier. Your way makes af easy, other way allows better plug/engine access.

[Coultl]

Honestly, the back corner is probably a better position for the air filter. I'm running up front because I 'think' i can create air filter housing that will look good in the engine bay. I'd like there for to something that hints at the upgrades...but also looks like it could have been stock. It's hard to tell from the images, but the filter is located where the electrical panel is (which I will be removing). I think it will tuck into the space nicely.

[Coultl]

I’ve been busy getting the engine rebuild on track. Everything that needs machining has been sent so I’m hoping to get back to the design work.

I picked up a 964 oil cooler for the water to air intercooler radiator. I thought I was clever because of course it would fit…but now I see that I was probably wrong. The battery bump takes up a ton of room. Hoping I can make it fit as it would be nice to use a Porsche part…and it was cheap.

[Coultl]

I’d love to run the same plug and coil that I run on my 5 cylinder Audi. VAG coil and FR5DTC plugs… a solid combo. I just found that the FR5DTC is used for the 964. Do you all know if anyone has used it for a 3.2??? I’m going twin plug and I can’t see a reason why it wouldn’t work.

[quattrorunner]

Originally Posted by Coultl

I’d love to run the same plug and coil that I run on my 5 cylinder Audi. VAG coil and FR5DTC plugs… a solid combo. I just found that the FR5DTC is used for the 964. Do you all know if anyone has used it for a 3.2??? I’m going twin plug and I can’t see a reason why it wouldn’t work.

I’d measure everything and if it’s same measurements I’d throw them in.