944S2 16V Turbo Build

[Thom]

Good work.

How hard was it to take the flanges off the cross over pipe without damaging the tubes at all? A friend building his own 16V engine has not been very successful with this so far.

[BasHenneman]

Nice work Luke! Why did you retain the stock xover small pipe? The stock wg location / pipework is horrible and you would benefit a lot from a fresh one!

[Bergerac]

Good work.

How hard was it to take the flanges off the cross over pipe without damaging the tubes at all? A friend building his own 16V engine has not been very successful with this so far.

The rear flange was already cracked so it didn't take much to get that off, the front one the weld was super hard and it got a little chewed up by the die grinder. I've given it to a fabricator to weld because it's beyond my skill, hes going to clean it up and realign the flanges so it's not under so much tension when we put it back on.

[Bergerac]

Nice work Luke! Why did you retain the stock xover small pipe? The stock wg location / pipework is horrible and you would benefit a lot from a fresh one!

It was a compromise to get the car running sooner. I do want to revisit the crossover but my fabricator is super busy. I'm also limited in what I can do with a RHD drive car around the headers/merge point.

[michaelmount123]

This is a fantastic build. It's also a great model for others considering a 4V turbo project. The quality and attention to detail are top notch. Good stuff!
MM

[Bergerac]

This is a fantastic build. It's also a great model for others considering a 4V turbo project. The quality and attention to detail are top notch. Good stuff!
MM

Thanks for the kind words, we couldnt manage quick or cheap on this build so we focused on quality.

Good work.

How hard was it to take the flanges off the cross over pipe without damaging the tubes at all? A friend building his own 16V engine has not been very successful with this so far.

Ive just got my crossover and headers back from the fabricator and while he's done a great job we are having a great deal of trouble getting a seal on between the headers and crossover do the amount of warping on the S2 headers. Id recommend your friend leave the flanges on the crossover if he can and change the header flanges to the turbo type with the crush ring grove in them. We've had the flanges ground mostly flat, and have ordered some Remflex gasket material so hopefully that will solve the problem. Once everything is proven leak free its going off to be ceramic coated, dont pay too much attention to the headshield, it had to come off to repair a crack and the fabricator wasnt able to save it, its going to come off again and be replaced with some Zircotec Form I think.

The build on the new motor has mostly stalled now, I cant bring myself to spring for a new timing belt pulley cover when I have a nearly new aluminum one on the S2 motor so the belts and timing setup will have to wait until that motor is out of the car and parts can be removed.

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The Hayward manifold has caused quite a few issues which have been holding up getting the car started again, the clash with the water outlet pipe (solved), a limited amount of room to get the pipe through from the turbo outlet to the intercooler and a clash with the S2 AOS. We ended up having to weld an elbow to the turbo outlet and clock the throttle body 20deg so we can bring the piping out parallel to the balance shaft housing.

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We were planning to use the S2 lid on a turbo AOS but due to the angle of the outlet barb we only have 2mm clearance to the underside of the manifold. I have some fittings coming to mod the turbo lid so that we will hopefully be able to get a 3/4 hose out through the small gap that we have, along with the harness and vacuum lines that run through the area. I do have the AOS delete fittings on hand but there is very little clearance from the heatshield for the bottom fitting and I would like to avoid having to fabricate somewhere to fill the oil if possible.


Ive been a bit lazy with the photos lately, I will share some more soon.

[Bergerac]

I'm also really starting to wonder what to do about the intercooler, I currently have a stock one with the modified end tank, but would really like something with 2.5 in/outlets without having to cut any supports. SFR seems to be the only off the shelf option but Im not sure I could wait for them to get one finished for me.

[Thom]

Ive just got my crossover and headers back from the fabricator and while he's done a great job we are having a great deal of trouble getting a seal on between the headers and crossover do the amount of warping on the S2 headers. Id recommend your friend leave the flanges on the crossover if he can and change the header flanges to the turbo type with the crush ring grove in them. We've had the flanges ground mostly flat, and have ordered some Remflex gasket material so hopefully that will solve the problem.

Thanks. Swapping the flanges on the headers is what was done on mine, with no issue so far.

I'm also really starting to wonder what to do about the intercooler, I currently have a stock one with the modified end tank, but would really like something with 2.5 in/outlets without having to cut any supports. SFR seems to be the only off the shelf option but Im not sure I could wait for them to get one finished for me.

Maximising the cross section is not easy for sure and the SFR Stage 1.5 is probably not going to flow enough with an S2 head especially if you intend to use aftermarket cams with more duration, etc, but it should flow a little more than the stock core already. Don't you have a local welder who could sort you out with a custom unit? @333pg333 may know of some good addresses.

[Bergerac]

Maximising the cross section is not easy for sure and the SFR Stage 1 is probably not going to flow enough with an S2 head especially if you intend to use aftermarket cams with more duration, etc, but it should flow a little more than the stock core already. Don't you have a local welder who could sort you out with a custom unit? @333pg333 may know of some good addresses.

I do have a fabricator who should be able to do it, finding the optimum core will be the challenge I guess. Bell have a few 6" deep cores which look like they might be what SFR used for the stage 1.5, but I really need to pull the bumper off and measure a few things.

[Thom]

I have lost count of how many measurements I have made and how much thinking I have put into this over the years before finally having a custom IC made. So glad that this topic is for me finally solved for good. Apologies for venting, I know this is sounding like an old fart. In case you feel like ditching the A/C, which I don't think you will considering where you live, the company that made mine can still produce it. This will be with 2.25" tubes though, but that seems large enough considering the performance I am getting from my engine now.