I am in the process of upgrading my car and have been delayed by wait-times for the different parts. But now that I noticed this special section for modifications with nothing in it so far, I thought I'd start my thread even though I'm not finished yet.
Part of the reason for the longer than expected completion time is that as I've gone along, I've realized some new needs that needed taking care of - and as a consequence, new parts were needed.
The latest, and hopefully the last item for this first phase of upgrades, is B&B exhaust headers that I have been waiting for for the last 3 weeks.
The whole project started with me learning about the latest and the greatest turbos available for the 930s. I was reading about the Borg-Warner KKK based K27 HighFlow S turbo that is a hybrid turbo, reducing turbo lag by about 300 rpm and increasing the top end boost to that exceeding K29 performance levels due to tighter compressor housing, I believe the compressor wheel is one from one of the Garrett turbos. Also part of the design is a 3 inch inlet and venturi to decrease spool time by increasing velocity across the inlet. And the K27 HFS is supposed to be able to support 550hp. This by no means is an indication of how much hp my car will have.
So, shorter spool time, more top end power, to that matching or exceeding the K29, which is a big turbo, sounded good to me. Especially knowing that my old K27 cast unit that RUF used almost 20 years ago, probably has some issues with pin holes causing leaks etc.
So, I went ahead and ordered the turbo. Then I started thinking that by the same logic (and the fact that I also had read about it) the OEM unit is cast. They say by now 80% of those stock wastegates have pinholes due to condensation caused rust. They are put together like a valve with a guide and valve. In time that guide wears and moisture rusts the cast bottom.
In other words they don't hold air either and so they bleed. So, which Wastegate should I buy? The most popular amongst the Porsche enthusiasts seems to be the Tial 46mm. Apparently the Tial can flow alot of air and therefore will not allow boost creep, therefore keeping you at a more accurate boost level which equals more power, less lag & more reliability. But mainly reliability. And that's a good thing.
So, I ordered a Tial 46mm as well.
At the same time I was learning about the required air to fuel ratios for the various types engine uses: cold and warm idling, cruising and boost. It soon became evident to me that the required level of fuel flow for the boost in the new turbo was in question with my standard Euro Fuel Distributor. So, I also ordered an Imagine Auto modified Euro Fuel head that flows about 20% more fuel than the stock one.
Now, who's going to tune this new setup? Me of course! How would I know how to do that? Get an AFR display unit and an adjustable Warm Up regulator (I had a spare one, why? that's a different story). So, I selected an AFR display that fit nicely in a slot that's probably meant for putting your sunglasses and such. It's in the center console at the bottom part. The one from Western Motor Sports did the job nicely. I also sent my spare WUR to a guy in San Diego who makes them adjustable, for cold, warm and boost all individually and separately. The CO seems easy enough to adjust. Just an allen key and turn it.Of course you have to know where - a shaft sticking up conspicuosly next to the fuel head.
And two more late thoughts:
1. Will the new turbo get enough air flow from my stock headers? Oh my gosh - Probably not! So, I ordered the B&B headers that are sure to provide for a nicely rounded setup with sufficient flow, and according to advertizement, reducing spooltime by up to 800 rpm. I won't mention the advertized hp increases yet since I will want to dyno the car and I will then post the real RWHP that the car produces. So, the total reduction in spooltime should be about 1100 rpm. That would mean full boost at 2000 - 2500 rpm range, and best of all, continuing up till redline.
2. Another late discovery was the fact that the RUF design had eliminated the Blow-Off-Valve plenum setup, and had not replaced it with anything. This is clearly a shortcoming in the design. To cut a long story short, I ordered a billet diverter valve that will recirculate the air in between the shifts reducing back pressure to the turbo. Apparently, over time this could damage the compressor wheel. I already received the Diverter Valve.
Almost forgot, one more thing: One of the previous owners of this car must have removed the boost control setup (probably to use in their new car) and this car was left with a 1 bar spring in the wastegate, which seems to be the way most 930 owners run their cars actually.
So, I had to order this gadget from RUF. I already received it.
OK, so that's quite a couple of new items ordered. Who's going to put them in? First thought: ME!
I started by installing the adjustable WUR and the fuel head. Not being a mechanic and not really having had a lot of experience doing stuff like this, this turned out to be quite a task. For example, changing the fuel filter which was a pre-requisite for the new fuel head, was an unexpectedly unpleasant job. Took me many hours to do just that. I won't tell how many in order to be spared embarrassment.
Anyhow, the fuel head and the adjustable WUR (and the fuel filter) are in now and the car is going great. The WMS AFR display is also in and connected to the lambda control and the Bosch LSU 4.2 sensor.
For installing the turbo, and the headers, I have decided to let an excellent local outfit called CARR Industries do the job.
I'll attach some pictures here and when you see the header bolts you'll understand why I rather let someone else tackle those - on their backs under the car!! Just waiting for that bad boy to fall on his face.
OK, in the hopes that this long story is not getting boring, I'll attach a few pictures here, with short comments:
Here's the boost control gadget with it's support rack, and the diverter valve already connected to the large diameter elbow going into the air flow housing.
In the background, on my laptop screen: NevadaJack replying to Roberto![]()
The big spring will be crammed into the Tial wastegate.
The Fuel Filter on the left side next to the black permatune box:
(Of course the Intercooler and airbox have been removed in this picture)
The K27 HFS:
The new fuel head:
The Tial 46mm wastegate:
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