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My 931 performance mods
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GeorgeV  



Joined: 14 Mar 2010
Posts: 301
Location: Brisbane, Australia

PostPosted: Tue Feb 19, 2013 12:04 am    Post subject: My 931 performance mods Reply with quote

Hi All,

I bought a nice 931 in 2010 from my father-in-law. Had 70,000kms on it and he had had it from near new. Sorry about the size of the photos but I don't know how to change that.



Drove it for 6 months and had a ball. But I wanted more power, and then I read Ideola's Perfomance Upgrades article: that's when my problems started. So I got it converted to FI with an Adaptronic ECU. The guy who did it did not have a clue, so it never ran right after that.

Eventually I found someone who knew a lot more. By then it was blowing some smoke. Had the valve stem seals done but it still smoked, the turbo seals had had it. So I decided to get a Garrett (gt28rs with a.63ar) fitted rather than rebuild the K26. This required an adpater flange for the exhaust manifold.




This is the final job.







It put out 135rwkw on 12psi - this was nice. Then I moved from Canberra to Brisbane and the higher temps made the idle go haywire. Found a Porsche trained mechanic who found that most of the settings in the Adaptronic had not been touched. So I decided to switch to a Haltech PS1000. I've got no pics of the Haltech. With intake temperatures of 85deg, the mechanic set the boost low (9psi) and power went back down to 85rwkw - what a drag.

Car still didn't start and idle right. So I got the fuel tank removed and cleaned. You can see where they cut a hole in the tank to drain it properly and then sealed it with a 10cent coin. Tank was full of water and other crap. Replaced intank pump with original, and out-of-tank pump with a Bosch highflow pump




and got a Turbosmart fuel pressure regulator installed.



Also had the fuel tank sender rebuilt so the fuel gauge worked properly again.

I wanted 300rwhp so we decided to go for custom exhaust & inlet manifolds, and intercooler.

Here are the headers, etc. It took forever (months) to find someone who would do the headers.












Also got 3in stainless steel exhaust fitted








Here's a pic of the 951 radiator I had fitted when the Haltech went in.



And a Grant Corsa wheel.



Then it took forever (more months) to find someone to do the inlet manifold. This is the result.






Here it's been vapour cleaned and HPC coated.




You can see that the plenum has been cut off the original manifold and a new plenum has been welded on. It's now pointing in the right direction! Throttle body is for a Nissan RB20.

Then we decided to ceramic coat everything for heat. Warning: may need sunglasses to look at the following photos.

Timing belt cover


This is a better view of the headers


Dump pipe


Hot side of turbo?



Cold side of turbo?


Cam cover


Next will have all this fitted. Plus a PWR charge cooler, new oil cooler, and then a tune. I will provide more updates as they happen.

I want to thank everyone who contributes to this board. There's so much useful info here, regardless of whether you are doing some maintenance or blowing a ton of money on your 924. It's all been an inspiration in one way or another. Also, thanks to my wife for buying me a 924 book every now and again, so that I could remember what my car looked like.

Some of the parts that have been removed from the car are available if anyone is interested - turbo, wastegate, adapter flange for exhaust manifold. PM me if you're interested.

I also have a copy of the 924turbo workshop manual. I'm willing to scan a few pages here and there for people, PM me.

George
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1981 932 with mods:
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Raceboy  



Joined: 01 Mar 2004
Posts: 2284
Location: Estonia, Europe

PostPosted: Tue Feb 19, 2013 12:44 am    Post subject: Reply with quote

Nice mods and you better find someone who really knows how to tune the car as wrong tune in the turbo car will kill it quick.

I was scared to see that you had the GT28RS mounted upside down, luckily in later photos it was corrected. Mounting it even in steep angle will kill the seals, not even talking about upside down.

But I would suggest to change out the oil cooler lines asap to pressed steel braided ones because the regular clamps are barely good at holding even the cooling system together reliably.
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'83 924 2.5 16v Turbo, 470hp
'67 911 Irish Green hotrod, 2.4S
'78 911 SC 2.5 ss Turbo "Martini"
'82 924S/931 "Gulf" racecar, 330 hp, sold
'84 924, turbocharged, sold.
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Carrera RSR  



Joined: 08 Jan 2010
Posts: 1448
Location: Somerset, UK

PostPosted: Tue Feb 19, 2013 1:00 am    Post subject: Reply with quote

Wow. Some impressive work and money spent there. When do you think it will all be back together?

Keep the updates coming.
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1980 931 - forged pistons, Piper cam, CGT turbo, 951 ducted FMIC, custom intake, Mittelmotor dizzy & cam pulley, H&S exhaust, GAZ Gold, Fuch'ed, Quaife LSD
Now www.924board.org/viewtopic.php?t=34690
Then www.924board.org/viewtopic.php?t=31252
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WEASEL149  



Joined: 19 Aug 2005
Posts: 589
Location: UK, Sheffield

PostPosted: Tue Feb 19, 2013 2:48 am    Post subject: Reply with quote

Wow! I was just starting to get bored with 924 forums and then I get home from work and see this.

You've got some really cool stuff going on here - I love your exhaust headers/manifold and exhaust system.

Like Raceboy has said and as you probably already know, the tune is critical. Having said that, I think you have the potential to make some serious power here, beyond your goal, especially after freeing up the exhaust, which seems to be a limitation with the standard cast manifold once you get beyond 350hp@crank.

You may have found inspiration on here but you're also an inspiration to other 924 Turbo owners looking to tune their cars
Keep up the good work and good luck with the rest of the project!
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11332
Location: PacNW

PostPosted: Tue Feb 19, 2013 4:15 am    Post subject: Reply with quote

If you could crank out a few of those Garrett adapters, I'm certain you could find buyers for them.
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GeorgeV  



Joined: 14 Mar 2010
Posts: 301
Location: Brisbane, Australia

PostPosted: Tue Feb 19, 2013 2:25 pm    Post subject: Reply with quote

Raceboy wrote:
Nice mods and you better find someone who really knows how to tune the car as wrong tune in the turbo car will kill it quick. I was scared to see that you had the GT28RS mounted upside down, luckily in later photos it was corrected. Mounting it even in steep angle will kill the seals, not even talking about upside down.


Thanks. This is the problem with doing this stuff. It's too easy to find someone who doesn't know enough about what they are doing. Biggest problem with the initial fit of the turbo was that they didn't fit a restrictor and too much oil got into the turbo, and then into the inlet manifold.

Raceboy wrote:
But I would suggest to change out the oil cooler lines asap to pressed steel braided ones because the regular clamps are barely good at holding even the cooling system together reliably.


My mechanic picked this up also. All the blue hose willl be tossed out when the new cooler is fitted.
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GeorgeV  



Joined: 14 Mar 2010
Posts: 301
Location: Brisbane, Australia

PostPosted: Tue Feb 19, 2013 2:28 pm    Post subject: Reply with quote

Carrera RSR wrote:
Wow. Some impressive work and money spent there. When do you think it will all be back together?

Keep the updates coming.


Thanks. Everything is being assembled now, so should be ready in...12 months. Well, maybe 1 or 2 months, this stuff takes forever.
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GeorgeV  



Joined: 14 Mar 2010
Posts: 301
Location: Brisbane, Australia

PostPosted: Tue Feb 19, 2013 2:30 pm    Post subject: Reply with quote

WEASEL149 wrote:
Wow! I was just starting to get bored with 924 forums and then I get home from work and see this.

You've got some really cool stuff going on here - I love your exhaust headers/manifold and exhaust system.

You may have found inspiration on here but you're also an inspiration to other 924 Turbo owners looking to tune their cars
Keep up the good work and good luck with the rest of the project!


Thank you for the kind words.
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GeorgeV  



Joined: 14 Mar 2010
Posts: 301
Location: Brisbane, Australia

PostPosted: Tue Feb 19, 2013 2:32 pm    Post subject: Reply with quote

Rasta Monsta wrote:
If you could crank out a few of those Garrett adapters, I'm certain you could find buyers for them.


If someone wants to buy it and make copies for other people, I'll be happy to go along.
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daniel  



Joined: 18 Jun 2009
Posts: 606
Location: Sydney, Australia

PostPosted: Tue Feb 19, 2013 4:11 pm    Post subject: Reply with quote

Who made the headers? Thats real neat work.

Also, I ran my exhaust in my race car right past the starter like you did, ended up killing the starter. Not to worry though, I got a gear reduction one from ideola that handles the heat AND the compression.

Cheers

Daniel

PS if you ever bring the car to Sydney let me know and we'll catch up for a chat, or take her for a run to Wakefield next time im there
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peterld  



Joined: 10 Dec 2006
Posts: 658
Location: Noosa Heads QLD Australia

PostPosted: Tue Feb 19, 2013 6:52 pm    Post subject: Reply with quote

Holy Snapping Duckfeathers.......
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leadfoot  



Joined: 11 Dec 2002
Posts: 2222
Location: gOLD cOAST Australia

PostPosted: Tue Feb 19, 2013 7:08 pm    Post subject: Reply with quote

good shit so far....
what are the engine / clutch details??

P.S another lovely brown interior.... hehe
Stu
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Joes924Racer  



Joined: 03 Nov 2002
Posts: 11965
Location: Oregon, Denver Colorado native!

PostPosted: Wed Feb 20, 2013 3:35 am    Post subject: Reply with quote

Yea very nice, nice work (keen on the header design.) nice pics,
nice upgrade .
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GeorgeV  



Joined: 14 Mar 2010
Posts: 301
Location: Brisbane, Australia

PostPosted: Wed Feb 20, 2013 9:39 pm    Post subject: Reply with quote

daniel wrote:
Who made the headers? Thats real neat work.

Exhaust Innovations, Capalaba, QLD. I sent him links to Steve Bassington's 931 (https://picasaweb.google.com/111470514161382354517/SteveBassingtonS931?gsessionid=SCfSDOrYgX9M1FtR3HXLNw) and Flosho's (http://www.924board.org/viewtopic.php?t=33337&postdays=0&postorder=asc&start=180) for inspiration.

daniel wrote:
Also, I ran my exhaust in my race car right past the starter like you did, ended up killing the starter. Not to worry though, I got a gear reduction one from ideola that handles the heat AND the compression.

Thanks for the warning. A starter from Ideola is on my list for the future.

daniel wrote:
PS if you ever bring the car to Sydney let me know and we'll catch up for a chat, or take her for a run to Wakefield next time im there

Thanks, Daniel. I'll take you up on that if I drive down there.
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GeorgeV  



Joined: 14 Mar 2010
Posts: 301
Location: Brisbane, Australia

PostPosted: Wed Feb 20, 2013 9:43 pm    Post subject: Reply with quote

leadfoot wrote:
good shit so far....
what are the engine / clutch details??


Thanks, Stu. Engine & clutch are stock and stock...until they blow.
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