cheap 3.2 turbo conversion

[raceman]

There`s always a cheaper way to do things and most Porsche owners don`t take it . Because we love our cars so much and because the expensive stuff is just too cool to pass up we tend to do mods right and not skimp on the goods.Most of us are well informed bargain hunters though.To do a N/A 3.2 turbo conversion "right" some may argue that one needs to go into the engine,replace pistons(lower compression) and a lot of other parts that will allow longevity.We know that but this post ids about the cheap way,not the Bill gates way.l`ve discovered in the course of my 3.2 turbo conversion that the transformation is surprisingly inexpensive.This is where l am in the cash outlay department and l`m almost done Header kit(includes gaskets,oil lines,turbo oil accumulator tank,etc $1930.00 shipped from Mid America.l saved $400 here because the kits are on sale.Keep in mind though that used headers are available for a huge savings over this,my largest purchase. So let`say l bought a used complete system for $500.00. Add turbo and wastegate for $270.00(Ebay,used),intercooler and all required tubing with blow off valve(Ebay,new) for $600.00 shipped.From Promotive come the chip and rising rate fuel pressure regulator for about $800.00 shipped.This is a hit but l know these parts work so it`s cheap insurance.l bought an adapter for the airflow meter to accept the intercooler elbow and a K&N came with,$65.00.Add $100.00 for misc. and l`m at $2345.00!! l already have a complete MSD/Nology ignition and a new fuel pump. This conversion can be done for $2500.00 !!! A boost guage and manual boost controller are also key items but l had those from a Subaru project. Because l bought the B&B headers with heat l`m at ,what $3750.00? Pretty cheap for the horsepower l`ll be seeing. l know none of this means anything if l overboost the engine and have a melt down.l`ve turboed several N/A engines in the past and with the exception of my first conversion l`ve had great success.l`m planning to run conservative boost and l`ll only be using my NOS system to cool the huge intercooler l had custom made.Cooling is important,l learned that the hard way.l wasn`t trying to do this the very cheapest possible way but it worked out that l got some good deals.l suspect l`ll be upgrading the turbo in the future but everthing else seems pretty tight P.S. l`m still not sure what l`m doing about a muffler,so add some $$$$ there. l expect about $100.00-$175.00

[Az911]

wow that is one large paragraph. Hit the enter key once in a while.

[raceman]

what`s a paragraph? is that like an intercooler? l`ll drive up a hill if l`m looking for a grade amigo,this forum is about the cars. Anyhow thanks for the input about the paragraph key,l never knowed nothin about it.

[K. Roman]

Maybe this will help.


There`s always a cheaper way to do things and most Porsche owners don`t take it .
Because we love our cars so much and because the expensive stuff is just too cool to pass up we tend to do mods right and not skimp on the goods.
Most of us are well informed bargain hunters though.To do a N/A 3.2 turbo conversion "right" some may argue that one needs to go into the engine,replace pistons(lower compression) and a lot of other parts that will allow longevity.We know that but this post ids about the cheap way,not the Bill gates way.l`ve discovered in the course of my 3.2 turbo conversion that the transformation is surprisingly inexpensive.
This is where l am in the cash outlay department and l`m almost done Header kit(includes gaskets,oil lines,turbo oil accumulator tank,etc $1930.00 shipped from Mid America.
l saved $400 here because the kits are on sale.Keep in mind though that used headers are available for a huge savings over this,my largest purchase.
So let`say l bought a used complete system for $500.00. Add turbo and wastegate for $270.00(Ebay,used),intercooler and all required tubing with blow off valve(Ebay,new) for $600.00 shipped.From Promotive come the chip and rising rate fuel pressure regulator for about $800.00 shipped.
This is a hit but l know these parts work so it`s cheap insurance.l bought an adapter for the airflow meter to accept the intercooler elbow and a K&N came with,$65.00.Add $100.00 for misc. and l`m at $2345.00!!
l already have a complete MSD/Nology ignition and a new fuel pump.

This conversion can be done for $2500.00 !!! A boost guage and manual boost controller are also key items but l had those from a Subaru project. Because l bought the B&B headers with heat l`m at ,what $3750.00?
Pretty cheap for the horsepower l`ll be seeing.
l know none of this means anything if l overboost the engine and have a melt down.
l`ve turboed several N/A engines in the past and with the exception of my first conversion l`ve had great success.
l`m planning to run conservative boost and l`ll only be using my NOS system to cool the huge intercooler l had custom made.Cooling is important,l learned that the hard way.l wasn`t trying to do this the very cheapest possible way but it worked out that l got some good deals.
l suspect l`ll be upgrading the turbo in the future but everthing else seems pretty tight P.S. l`m still not sure what l`m doing about a muffler,so add some $$$$ there. l expect about $100.00-$175.00

[beepbeep]

Interesting project!

But i wonder how you plan to use OEM 930 headers w/o specialized scavenge pump as turbo has to be
higher up and slightly offset than in 930 in order to use gravity drain into lower cam cover (which I guess you'll be using as you didn't mention any sort of scavenge pump).

Rising rate pressure regulator is also somewhat unnecessary as it frequently messes up the mapping. It might be smarter to just use six bigger injectors and leave OEM pressure-regulator in place. That way, you can buy a copy of someone others chip w/o added uncertainty of how how your RRPR was adjusted compared to his/hers.

People often tend to believe that 930 parts are some sort of magic bullet that fit's right on and makes their conversion walk in the park. Most of the time, they aren't compatible or a just not optimal.

I believe that one of cheapest ways to turbocharge Carrera engine should look like this:

1. Cut and weld end of OEM euro-style headers so it goes into the turbo that sit's somewhat higher than OEM 930 ones and drains into lower cam cover.

2. Using second-hand turbo with built-in wastegate (saves weight, money and hassle).

3. Six second-hand injectors, slightly bigger than OEM

4. Copy of someone others fuel chip, from a car that uses Bosch Motoronic

5. Maybe a hot-wire AMM.

[JP911]

Why bother with all this expensive OEM parts hoo-ha when you could simply use one of these: http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&item=7913916536&category=33742

[sammyg2]

There is always a way to get something done without paying a huge amount of money.
I turbocharged my SC for under $1200.
I was lucky enough to find a very good deal on a used kit but my point is, if you are willing to do your homework and legwork and invest your labor you can get a project done right for a fraction of what it would cost to have someone else do it, your example is proof.

The tricky parts of a DIY project are:
compromise and judgement.
A budget can be a dangerous thing if it causes one to over-compromise to save money or if the quest to do it cheaply affects your judgement and reduces the quality of the finished project. It is a fine line to walk. I've found it helps to define exactly what I want to end up with rather that how much I want to spend at the begining.
I work towards the end result while trying to find the least expensive way to accomplish each step all the while focusing on the finish line, not the $$$.

I have no doubt you will accomplish your goal and save money at the same time. Good luck and keep us posted.

[raceman]

thanks for the feedback.And Beep l do plan to use a tilton pump for the turbo which will have oil recirced back to the oil tank.Add $300.00...As for the use of bigger injectors Promotive has created a chip/FPR combo for the 3.2 that is proven to work very well and seems to me to be the safest route.l don`t know of a turbo with built in wastegate that will flow enough for the 3.2 on low boost.The wastegate would be open all the time,creating problems.l paid $275.00 for my turbo and wastegate,both Porsche parts that bolt on.Part of the economy here is that l don`t have to spend weeks searching for parts and fabbing up one-offs.l`m trying to get the job done right for the least money and for me using Porsche turbo parts to start with is the most economical time wise.Now if this were a Saab engine we were talking about...

[iamchappy]

Think twice about using the Tilton pump for scavenging the oil, I am currently using one for mine and it hasn't kept up with the turbos flow, The 930 pumps attached to the cam would be a better choice even though you will need some fabricating done.
I would fabricate something like the BAE kit crossover pipe and drain into the tensioner cover, much easier and fewer problems to deal with.

[raceman]

Hmmm,l was planning to drain into the valve cover but l wasn`t sure the turbo would be high enough when using the stock 930 location.But if it IS high enough to gravity drain then that`s what l`ll do. l like the simplicity.Hey Chappy,where do you get the oil feed from for the turbo? do you use the oil pressure sending unit port? Any help appreciated

[iamchappy]

Oil pressure sending unit is where I'm tapped.

[WydRyd]

You CAN modify the 930 headers (the collector portion) to mount the turbocharger high enough for gravity drain. Don't waste ur time with an electric scavenge pump. What if it fails? DOH!

The safest way is to just make an adaptor piece that mates to the 930 header which mounts the turbo a few inches higher. That way, you can use gravity drain AND also replace the muffler with replacement 930 headers in the future, if need be.

That's similar to what I've done. I've used a Mille-Miglia 930 muffler with an extension piece fabricated to mate to the Turbo's exhaust housing. If I need to swap the muffler out in future, all I need to do is get a 930 unit and swap it in. Easy!

[david.avery]

I would love to do this; a low boost turbo would make the 3.2 an awesome performer... I wish someone would offer a kit for say 3K less some easily sourced parts, it would sell like hot cakes. If I could get 250-275 RWHP, that would make my car perfect, IMO.

Raceman, what are you expecting HP wise?

[Joeaksa]

I turbo'ed a Volvo years before the factory came out with their version. Strictly a bolt on project and no compression change.

Pulled a turbo off of the shelf at work (I play with airplanes from time to time) and bought a wastegate that was welded to the exhaust manifold. Friend made an adapter to fit the turbo to the exhaust manifold and the rest just sourced here and there.

Ran for years with no problems at all but I kept the boost under 10 PSI and ran good fuel in the car. Ran like a scalded a$$ ape and totally transformed the car. If its done correctly you can improvise and make it work for a lot less money.

JoeA

[cowtown]

What's the compression and boost level of your project, raceman?

[WydRyd]

Since he's not touching the internals to lower the compression (stock 9.5:1), I'd say 0.7bar, intercooled

Good for ~400 FWHP

[david.avery]

Also, raceman, pics, pics, pics, please, please, please

[raceman]

hey thanks for the replys amigos.Pics? give me a few days.l don`t think l can really move the turbo up any higher but l`ll check.l may just use a spacer if l can. As for horsepower Promotive claims almost 400 with their stage one kit and that`s the chip and FPR l`ll be using.l`ve improved on the Promotive kit though because l have a monster intercooler and high flow headers. l`ll be more then happy with a safe 300-350 hp running 9psi. l plan to use the nitrous system l have to flash cool the intercooler and l may plumb a nitrous jet into the turbo to eliminate lag. l have to do more research on that though.l have no regrets on undertaking this conversion and the best part is that selling my almost new complete GHL exhaust and Autothority Mass Flow has covered more then half the cost so far.Pics will have to follow,you have to see this!

[dickster]

interesting project.

the thing that puts me off this and in the direction of a bolt on kit is the thought of fabing the pipework.

how much of the plumbing do you have to fab?

[raceman]

Pipe work? not much to do actually.There is the charge pipe from turbo to intercooler but it`s pretty much a straight shot so some silicon couplers and maybe a short length of tubing.Then there`s the intercooler exit to the flapper box which needs a silicon elbow. l may just mount the blow off valve on the intercooler for simplicity.The intercooler is custom for the car so inlet/exit are where they need to be.The way l bought parts everthing is really straight forward.l chose this route because l didn`t want to be bogged down with a lot of fab work and custom parts sourcing.l bought the intercooler,blow off valve and all the tubing,connectors and elbows from "goingsuperfast" who sells 3.2 turbo conversion parts.Great prices.He makes a fantastic header system for $900.00 but l needed heat so l had to go with the B&B.This is not as hard or expensive as you might think.Keep the boost relatively low on a healthy engine and you don`t need to go inside.From Carrera to Turbo Carrera for less then $4000.00 !!! pics will follow