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morghen · Joined: 21 Jan 2005 Posts: 9102 Location: Romania

I have some plans for the turbo:

1. Intercooler
2. Boost controler + blow-off(i was told that this makes the turbo last longer)
3. EFI

So...i need advice and examples of already done jobs in this perspective.
The first step is the intercooler...EFI will come later.

1. I need to know what would be the optimal size of the intercooler. Ofcourse that the FMIC is the best but what is the optimal size...not to induce too much lag and still make a big difference compared to stock.
I need to mention that i'm NOT going to use a 951 IC as i'm going for a custom IC. I am going to use CIS for the begining.

2. Are there boost controler kits availabe? i would like to increase the boost a bit...maby 1.0 bar.

For the begining i sketched the IC size and mounting place. If i can get the IC mounted there and the piping to sneak between the radiator and the body of the car i'm great

(going to use 50mm pipes for the intake)
The plan is to remove the intermediare pipe from the turbo to the upper pressure duct and mount 2 90° pieces going to and coming from the IC. The rest the pipes remain stock units.
Tell me what do you guys think.

Shot at 2007-07-29

Shot at 2007-07-29
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Lizard · Posted: Mon Jul 30, 2007 8:25 am Post subject:

I would take a much different route.

First go to EFI,
THEN intercool, the main reason for this is there is not enough room to do what you want with the size of piping you will need for this. As well you should ditch the tube which goes over the valve cover.

As well the factory turbo has a BOV or as Porsche likes to call it a POV or recirculation valve built into the compressor side of the turbo.

If you go with a later model turbo with a custom exhaust manifold then yes by all means add a BOV
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3 928s,

endwrench · Joined: 07 Dec 2002 Posts: 1631 Location: Victor, Montana

I have to go with Lizard on this. EFI first. This will also open up many other choices for IC. Your plumbing wont be dictated by the fuel distributor. Also, the EFI will give probably give you some sort of built in boost control you can play with before going IC. You may even consider a dual MAP setup with methanol injection instead of IC altogether. All I'm saying is EFI opens up a whole lot a different options you haven't had the chance to think about.

Todd
_________________
'79 924NA. Rebuilt 9.5:1, MSDS header, Mega Squirt Injection, MJLJ-EDIS Ignition, 1.6L Whipple Charger and Intercooler, 10lbs Boost, 944 Trans, Custom HD Clutch.
"simsport" said....superchargers are better than turbos its official!....

bruce76-924 · Joined: 22 Feb 2007 Posts: 105 Location: Bradford, England

I'm seconding Lizard and Endwrench on the "efi first" option. You only have to look back at the pictures of my engine, which is running CIS to see that efi is the only practical way forward. The CIS set up doesn't lend itself well to intercooling hence the poor factory set up on the CGT. Go efi and with some sort of mappable ignition, it will save you loads of hassle in the long run and give you much better gains. (I've done the high boost, intercooled CIS option and it's problematic, awkward and temperamental, but DIY efi wasn't around at the time)

Cheers Bruce.
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1976 924 LHD, full cage, semi tube chassis, 951 brakes, lightweight 951 body panels.
1.8t engine conversion with Holset turbo and 6 speed Audi gearbox.

morghen · Joined: 21 Jan 2005 Posts: 9102 Location: Romania

ok guys...hit me !

Tell me whats the most easy/cost-effective/performant sistem that i can get.
I was told Megasquirt. What do i need to do? will i have to replace the stock ignition?
What does MS include? just an ECU that controls the injectors in relation to throtle position,rev,boost oh and engine pase

?
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endwrench · Joined: 07 Dec 2002 Posts: 1631 Location: Victor, Montana

MS1 V3 is the cheapest setup. Go to there site and read the manual. It will explain everything. It seems daunting at first but there will be plenty of help from all the board members here so you are not pioneering this whole thing by yourself!

http://www.msextra.com/manuals/MS_Extra_Basic_Configuration_Manual.htm

http://www.msextra.com/index.php

Todd
_________________
'79 924NA. Rebuilt 9.5:1, MSDS header, Mega Squirt Injection, MJLJ-EDIS Ignition, 1.6L Whipple Charger and Intercooler, 10lbs Boost, 944 Trans, Custom HD Clutch.
"simsport" said....superchargers are better than turbos its official!....

-nick · Joined: 16 Nov 2002 Posts: 2699 Location: Cambridge, MA

Yep, pour yourself a drink and start here:

http://www.megamanual.com/v22manual/mtabcon.htm
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1980 931S
15psi boost, MS-II, EDIS, 951 IC, custom intake, Ford 5.0L throttle body, Forge BOV, WB o2, G31 w/LSD, 964 wheels, 968 rear sway, Bilsteins, 200# Welt. springs. A laptop, and a partridge in a pear tree.
1991 964 C4 Cabriolet

morghen · Joined: 21 Jan 2005 Posts: 9102 Location: Romania

ok i'm going to try and understand what goes on with this mega..squirt.

I found a NEW 0(zero) Km early 944 gearbox for sale

its mine !. This gearbox should be a short ratio one...my knowledge is that early 944s were preety quick due to shorter ratio gearbox and lighter body.

BUT i cant find a damn torgue tube for this gearbox.
I am not going to use the snail-shell because its got a bad 2-nd gear syncro and honestly...its stupid...i cant stand the Reverse being there...i always gring it when changing to second or even back to first.
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flosho · Posted: Wed Aug 01, 2007 7:09 am Post subject:

flosho · Posted: Wed Aug 01, 2007 7:28 am Post subject:

morghen · Joined: 21 Jan 2005 Posts: 9102 Location: Romania

hmm..they say something about a CAM sensor...and NOT a crank sensor...what about that? all i've heard you guys yap about was crank sensors...

EDIT: how much would a new 2-nd gear syncro for the ROW snailshell cost? and woud it be much of a hastle to replace it?
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-nick · Joined: 16 Nov 2002 Posts: 2699 Location: Cambridge, MA

Re: syncro - the 1-2-3 syncro's are actually very easy to replace. You'll need an impact wrench/air gun to take off the big nut on the front of that shaft and a simple gear puller to remove one pressed-on piece (easy). Then it's just a matter of popping out the old syncro and popping in the new one. Search for CMXXXI's G31 post on rebuilding.

Absolutely agree with flosho - you won't completely understand it until you get your hands dirty. The manual will give lots to chew on and when you have a question, you can either search more specifically in the manual, or sound smart when you ask it.

Cam sensors/triggers are typically only for sequential injection. Although I think MS has the ability to use a cam trigger instead of a crank trigger. The crank just rotates twice as fast.
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1980 931S
15psi boost, MS-II, EDIS, 951 IC, custom intake, Ford 5.0L throttle body, Forge BOV, WB o2, G31 w/LSD, 964 wheels, 968 rear sway, Bilsteins, 200# Welt. springs. A laptop, and a partridge in a pear tree.
1991 964 C4 Cabriolet

endwrench · Joined: 07 Dec 2002 Posts: 1631 Location: Victor, Montana

Cam sensor can be used for phasing a wasted spark setup. You don't need to concern yourself with it. I suggest EDIS or locked distributor for spark. Simple and bullet proof.

Good luck finding parts for you tranny. I'd go with the 944 tranny myself. I have the early one and and the gearing is pretty much identical to the snail 1st 2nd and 3rd with 4th being much shorter and 5th a little taller. 4th is great fun at highway speeds

Todd
_________________
'79 924NA. Rebuilt 9.5:1, MSDS header, Mega Squirt Injection, MJLJ-EDIS Ignition, 1.6L Whipple Charger and Intercooler, 10lbs Boost, 944 Trans, Custom HD Clutch.
"simsport" said....superchargers are better than turbos its official!....

Min · Posted: Wed Aug 01, 2007 9:34 am Post subject:

morghen · Joined: 21 Jan 2005 Posts: 9102 Location: Romania

well i have just been droped the price of that new gearbox on my feet...he bought it for 200 EUR and wants 1000 for it. So i 'm thinking of replacing the syncros. How much would they cost in the states? i'm sure that i cant get them ordered on a local parts shop.

EDIT: ok..maby i did not read enough but...do i also need to change the stock spark system if i install MS ? its an S2....i find it preety good..
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