In reply to johnnytorque:
sounds like it is hitting all the right buttons for you then!
Keep up the beautiful work!
In reply to johnnytorque:
sounds like it is hitting all the right buttons for you then!
Keep up the beautiful work!
Damnit, Costco Canada has all the best deals. Scissors lifts, BlueStar kitchen appliances...
Spring/Summer 2015. I live in the great white north and come November, toys get put away. It's a sad time, I so wish we had Florida type weather in Canada
All depending on where you live in Canada that is....:)
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Just joined the forum after reading your thread! Cool car! I really like 944s and am a big fan of superchargers so thumbs up from me! I run an eaton m45 from a Mercedes e200k on my ford puma (little European 2 door 'coupe' with a revvy 1.7 16v motor) and did the conversion myself, although not as cleanly as yours! I just wanted to share a few bits of info I picked up on doing my conversion and in running the car. Firstly, the one which I think will most likely cause you headaches, the dump valve, blow off valve, recirculating valve, whatever you want to call it. I run the exact same unit on mine, and even with my poxy blower running about 5-6psi it isn't man enough for the job. I have blown off hoses more times than I can remember now, by having the car above 5000rpm and closing the throttle either too quickly, or allowing the car to sit at high rpm for more than a few seconds with the throttle closed. I can guarantee you'll have the same issue with the m90. The stock systems across the board normally run a mechanical bypass valve of a similar diameter to the boost pipes. I planned to just add a second identical vacuum operated valve, which will hopefully stop this problem.
Secondly the belt/pulley arrangement. Mine runs a 5 rib as opposed to the 7 rib that the blowers pulley is designed for with no issues, I think at the level of boost you're gonna be running you shouldn't have an issue either. The link posted before, which you said offered pulleys for gm models, it shouldn't make an difference. The blowers are made by the same company (eaton) and so pulleys are interchangeable as far as I'm aware.
As for speccing the pulley size for the boost/power you want to run, this little calculator might come in handy. It was pretty spot on for my application, I was down about 5% on the estimated power figure but I guesstimated some of the factors (and my setup is pretty ghetto!)
http://autoapps.eaton.com/Simulator/EngineDetails.aspx
Good luck getting it all setup and running come the better weather, you'll be grinning ear to ear first time you get to drive in it anger I'm sure!
So looking at this I'm assuming you moved the alternator lower to fit the supercharger? Did you remove the AC compressor and use something like the Broadfoot alternator bracket? I can't tell if you've lowered the alternator or not from the pictures. I was thinking about moving to the Nissan Quest alternator which is smaller - if I could keep the AC that would be optimal. Overall I love the idea. I'm already running a Rogue ECU setup, and like you I have enough fab background that I know I can pull this off. I was going to put a turbo on it just to spite all the 951 guys that harp on all the NA guys who even bring up the idea, but this looks like it would be less work, and like you I love the sound of the supercharger. I'm not looking to hoon the E36 M3e out of this thing, I just want the power to match the chassis dynamics... I rebuilt the motor, clutch, torque tube, transmission (with LSD), suspension (Koni Sport and new bushings all around), and bigger brakes all the way around. The chassis is ready to have a little more kick, and I love this idea. Did you use and setup the stock air bypass manifold off the back in addition to the bypass that you added? I assume you didn't, but the stock setup seems like it would work nicely, but the plumbing doesn't look advantageous. And last question, do you have any pictures of how the mounting bracket is setup. I'm sure I can sort something out myself, but if I had a drawing or a couple of good pictures I'd appreciate the head start. I've bid on a supercharger already, hopefully I can have it before next weekend and I can start setting things up. I've already mounted a huge intercooler, and have the tubing ready to fab up the intercooler hoses, so If I get a bracket fabbed up it won't take me long to finish up running the plumbing, and then move on to tuning the Rogue ECU for boost. If I have to I have a MegaSquirt setup that I can piggyback and use it to help fine tune the setup. Once I have the parts I'll try and setup a project post here and I'll link it to yours.
Some stunning fab work, can clearly tell a lot of thought and effort went into this one.
Looking forward for spring thaw, there's nothing better than those first few spring weeks in Canada when the temperatures get high enough to watch sports car owners rediscover their clutch engagement points and throttle mappings.
I might just be the worst build thread guy ever. 
I spent the spring doing maintenance to the car. Waterpump, belts, seals, rollers, gaskets etc. Everything on the front of the engine is new. I also took the time to clean up some of the vacuum lines and cranckcase hoses as well as removing the idle air control. I also installed an offset cam key to advance the cam by 4 degrees which seems to have really woken up the car! The car is running amazing. I was chasing some driveability issues last year that I think I sorted with running the vacuum lines properly. It runs around 5 lbs of boost so the engine should last a while and the power now suits the car perfectly. Gobs of low-end torque and it will easily break the tires loose in first and second gear. I'm pretty sure the brakes will have to be my first upgrade, we'll see in two weeks when I run it at Mosport for a Porsche Club DE.
I always said with 40 or 50 more HP the 944 would be the perfect car, I was right. 
In reply to johnnytorque:
You might be the worst build thread guy, but your build is spectacular. I never caught it until now, but damn--top notch fab there. Fab porn.
Glad it all works! 
So wheres some video of this machine?
Crappy video here.
So looking at this I'm assuming you moved the alternator lower to fit the supercharger? Did you remove the AC compressor and use something like the Broadfoot alternator bracket?
JT - That is exactly what I did. Makes lots of room for the SC.
I can't tell if you've lowered the alternator or not from the pictures. I was thinking about moving to the Nissan Quest alternator which is smaller - if I could keep the AC that would be optimal.
JT - I agree, I'd love AC but it's a pretty focused track car so it's not a big deal.
Overall I love the idea. I'm already running a Rogue ECU setup, and like you I have enough fab background that I know I can pull this off. I was going to put a turbo on it just to spite all the 951 guys that harp on all the NA guys who even bring up the idea, but this looks like it would be less work, and like you I love the sound of the supercharger. I'm not looking to hoon the E36 M3e out of this thing, I just want the power to match the chassis dynamics...
JT - I agree 100%. I'm only actually running 4-5 lbs. boost but it's a nice little extra kick.
I rebuilt the motor, clutch, torque tube, transmission (with LSD), suspension (Koni Sport and new bushings all around), and bigger brakes all the way around. The chassis is ready to have a little more kick, and I love this idea.
JT - You're further ahead than I was when I started. 
Did you use and setup the stock air bypass manifold off the back in addition to the bypass that you added? I assume you didn't, but the stock setup seems like it would work nicely, but the plumbing doesn't look advantageous.
JT - Nope, just an OEM Bosch bypass, no room for the T-bird SC bypass setup.
And last question, do you have any pictures of how the mounting bracket is setup. I'm sure I can sort something out myself, but if I had a drawing or a couple of good pictures I'd appreciate the head start.
JT - Only the pics at the start of the build thread.
I've bid on a supercharger already, hopefully I can have it before next weekend and I can start setting things up. I've already mounted a huge intercooler, and have the tubing ready to fab up the intercooler hoses, so If I get a bracket fabbed up it won't take me long to finish up running the plumbing, and then move on to tuning the Rogue ECU for boost. If I have to I have a MegaSquirt setup that I can piggyback and use it to help fine tune the setup. Once I have the parts I'll try and setup a project post here and I'll link it to yours.
JT - Very cool. Good luck on your project
So I have had a weird issue come up with the car in the last few days of driving it. I'll be driving along at normal speeds and all of a sudden the tach drops to zero and the car loses power. Sometimes it will catch again and keep going, other times it stalls but will instantly restart. I didn't touch anything electrical since driving the car last year so I am at a loss for where to even start. Based on the sudden tach drop, it is ignition related. I had a similar issue last fall where the DME had some broken solder joints and were causing a similar issue but it would stall and not restart unless I "tapped" the DME with my finger. I reflowed the solder and it was perfect after that.
I have checked all my chassis grounds, wiring, reference sensors, etc. and have found nothing.
Any ideas?
Ignition switch.
Thanks Turboswede, I did check into the ignition and all seems good there. I spent quite a bit of time cleaning up my dist. cap and rotor and that seems to have improved things. I went for a nice long drive on Friday to my mechanic and had no issues, he then took the car for a long road test and didn't have any stalling problems. I then drove home and no issues again. I hope to do some miles today in the cold, wet weather we're having to see if it shows up again.
On a positive note, my mechanic spent 1.5 hrs. going over the car and was thoroughly impressed. He road tested it and said it was now"the Perfect 944" He tracks a modified S2 3.0 powered NA car and says my car will give him a good run. Awesome!!
I still have loads of work to do. I am also debating whether or not to paint the car, the body is so rough it looks like such a beater but being so strong mechanically means I can almost justify it's shoddy appearance.
So my son and I went out driving this morning in the rain and found some fun dirt roads to test out the Supercharged 944. The car ran really well, but It's still rich Lots of power though and some really fun noises too.
what did you do with the headlight motor? it looks like it is missing in the pictures.
My headlights are manually operated. There was a guy selling a kit on rennlist that copied the setup the original Porsche 914-6 racecars used. It's super simple, super light, and gave me a ton more room to work with. It means I have to physically get out of the car, pop the hood, then manually raise or lower the headlights by hand, but it's a small price to pay. On a daily driver it would probably be a pain but on a track car it's golden.
johnnytorque wrote: My headlights are manually operated. There was a guy selling a kit on rennlist that copied the setup the original Porsche 914-6 racecars used. It's super simple, super light, and gave me a ton more room to work with. It means I have to physically get out of the car, pop the hood, then manually raise or lower the headlights by hand, but it's a small price to pay. On a daily driver it would probably be a pain but on a track car it's golden.
Awesome! can you post some close up pics of it?
So I took the car to Mosport for it's first track outing. The car was outstanding! So much more torque to get out of the corners and I was able to keep up with most of the last gen Boxsters and Caymans. Older 911's too.
I had an issue with some crankcase pressure so I am currently building a catch can setup. It's not done yet, I'm going to add some stainless steel "wool" type material in between the baffles.
Here's some pics of what I cobbled together today:
Also, here's a couple of pics of my headlight setup. I bought it off a guy on Rennlist that modeled it after the old 914-6 racecars.
Here's a quick little video of the car in action:
I'm curious what kind of power this puts down. I would love a 944 like this.
I wish someone like you lived near me so I have someone help (with monetary incentive) my dream RB30 supercharger build.
I had an issue last weekend at the track with my supercharged 944. The car ran amazing but I was having major crankcase venting issues. I was blowing a large quantity of oil out the dipstick hole. I tried a few different way to relieve it but was unsuccessful. So I built by own baffled catch can, installed it and went for a drive. The car isn't running well anymore(wasn't on the way home from the track either). My A/F readings are off, the car won't run in closed loop anymore(might be a fouled O2 sensor, not sure) and it just feels off. I took it for a drive and emptied the catch can when I got home and there was about an 1/8th of a litre in there(after 20 mins of driving). Also the car was running hotter than usual and being that it isn't hot out today that's cause for concern too. Thats a lot of oil for a short drive. So I brought it home and did a compression test. Here are the results:
Cyl. 1 - 160 Cyl. 2 - 195 Cyl. 3 - 160 Cyl. 4 - 160
What is up with cylinder 2?
The spark plugs are all pretty much the same, maybe looking a touch on the light side but I did lean out the tune a little for the drive home. It was still showing under 14.7 minimum on the AFR gauge and going rich at WOT.
Also there is oil at the base of the head under the intake manifold side leading me to believe the head gasket is gone, but in my experience, the coolant or oil would show signs.
I'm stumped. Based on what I am seeing I'm thinking head gasket, but why the increased cylinder pressure in #2?
Thoughts?
edit: you already said the plugs were normal for the most part, so my guess is bunk.
In reply to johnnytorque:
Maybe oil in no2 cyl increasing compression. If the engine isn't running well I would do a leak down test on each cylinder may be running too lean and cooked the piston rings. I run my engine at between A/F 11.5 to 13:1 if you're running a supercharger you need to put heaps of fuel in to cool the engine. This is how Porsche blew the 951s up a Le mans when the Porsche techs leaned off the fuel so the cars would go further between pit stops and they melted the pistons. How much boost are you getting? I am running 12psi at 5,400rpm and I redline at 5,600RPM to keep a bit more reliability. Usually large blow by means some piston cylinder damage has occurred. So leak down test will confirm.
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