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944 - VW Swap

 
Old 03-12-2015, 03:03 AM
  #31  
FRporscheman
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Nice!
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Old 03-12-2015, 03:54 AM
  #32  
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Oh my gosh! That's some serious fabricating you have going on there. Will you make the information regarding the modification done to the various components available to others? If your project works well enough, perhaps you can work with a company like Renegade Hybrids to market a conversion kit.
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Old 03-12-2015, 04:01 AM
  #33  
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Originally Posted by V2Rocket_aka944 View Post
How is the 944 thermostat a bad design?
99% of cases where people suspect a thermostat is due to using **** parts or neglecting maintenance.

The 944 thermostat is like any other thermostat and does its job well.
I threw mine in with the waterpump in 2012 and on 100*+ days, going uphills with AC on the water temperature still barely gets above the middle line. And in the snowy mountains in the wintertime I get heat in the cabin within a mile of driving when it's 30s F outside.

As for the 944 system...what's so complex about it?
Fill the water tank, water goes into the radiator, into the engine, back to the radiator.
If it gets too hot a small hose routes water back to the tank to expand.

Heater either lets water circulate to the dash or it doesn't, then routes back to the pump to recirculate and warm up you and the engine faster by (a rather ingenious solution IMO) running the return pipe over the exhaust manifold.
The 944 cooling system suffers from being more complicated than it needs to be. They should have placed the thermostat under the water outlet the upper radiator hose connects to. This is the obvious place for it, and would greatly simplify servicing. Not to mention allowing a MUCH simpler casting used for the water pump, which would allow those to be sold for MUCH less money. Putting the thermostat up the water pump like they have is pure silliness.
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Old 03-12-2015, 07:06 AM
  #34  
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OK, so basically you don't like the expensive water pump. But your way isn't really simpler. I too wish the WP was cheaper but oh well.
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Old 03-12-2015, 10:49 AM
  #35  
Lapkritis
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Originally Posted by tempest411 View Post
Oh my gosh! That's some serious fabricating you have going on there. Will you make the information regarding the modification done to the various components available to others? If your project works well enough, perhaps you can work with a company like Renegade Hybrids to market a conversion kit.
Thanks- my goal is to help out the community with this one rather than just making a one-off that works for only my personal car. I'm trying my best to show which parts we're using and how. The bell-housing is going to be a manufactured part (USA) rather than modified. We'll be prototyping more than 1 if we move forward with a casting run. The 3D scanning, Solidworks design and related general mechanical engineering is being done by tenured professionals in the aerospace industry. People far more skilled in the craft than I are lending their time and expertise to do this the right way.

A couple reasons for this:

1) The center hole for the Audi bell housing has to be knocked out for the Porsche flange due to interfering depths/thicknesses. While we could weld against what we have cut down, exact precision and repeatability could not be achieved with a quick hack. This ensures we don't encounter slight misalignment that may result in part failure such as a slightly misaligned pilot bearing or clutch engagement against the pressure plate/flywheel.

2) There is quite a bit of clean-up due to excess, unused material on the Audi housing that takes up real estate.

3) We may consider reorientation of the starter and clutch slave cylinder.

4) Some parts may convert to 944 type to save on new parts with the swap.

Quite fun to this point but I really want to drive it this year.
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Old 03-12-2015, 11:19 AM
  #36  
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Remind me - the BH will be a cast/fabricated 944 torque tube bolt-up unit, with a flange/depth designed to accommodate the VW engine/clutch package? Will it work on just the 1.8 or engines like the 2.5 I5 as well?
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Old 03-12-2015, 12:31 PM
  #37  
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The 2.5 I5's share similar bell housing as the Audi/VW 4cyls is my understanding. There appears to be plenty of room for another cylinder out front that's for sure.
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Old 03-12-2015, 02:19 PM
  #38  
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Originally Posted by V2Rocket_aka944 View Post
Remind me - the BH will be a cast/fabricated 944 torque tube bolt-up unit, with a flange/depth designed to accommodate the VW engine/clutch package? Will it work on just the 1.8 or engines like the 2.5 I5 as well?
The 07K (new 2.5) requires trimming/shaving of the top two bolts on a standard 01E/01A bellhousing. But the previous I5's (10v and 20v) along with V6/Most V8's/I4's will work with this bellhousing (VR6 will with an adapter).

The guy at 9Products made a prototype 944 bellhousing for an AAN already. Haven't seen updates in a long time though.

http://www.9products.com/blog


Last edited by alxdgr8; 03-12-2015 at 03:06 PM.
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Old 03-12-2015, 02:23 PM
  #39  
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Originally Posted by alxdgr8 View Post
The 07K (new 2.5) requires trimming/shaving of the top two bolts on a standard 01E/01A bellhousing. And it requires some work to fit the starter. But the previous I5's (10v and 20v) along with V6/Most V8's/I4's will work with this bellhousing (VR6 will with an adapter).

The guy at 9Products made a prototype 944 bellhousing for an AAN already. Haven't seen updates in a long time though.

http://www.9products.com/blog
I'm not interested in the AAN/old 10/20v stuff, it is simply too unavailable in the USA. There just aren't any of those engines around for the picking.

I much prefer your choice, the 07K as there are zillions for pennies. How different is the AAN/07K BH pattern>?
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Old 03-12-2015, 02:32 PM
  #40  
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Here's the starter cutout differences. You have to modify the rear timing cover:
Name:  20140323_160944_zpsj6z1pe2u.jpg
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And the solution:




And the top bellhousing trimming that needs done:

Last edited by alxdgr8; 03-12-2015 at 03:05 PM.
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Old 03-12-2015, 02:54 PM
  #41  
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I don't want to go too far on a tangent for a different engine but this appears to be the chain cover for the newer 5cyl (07K109211E) modified, not the bell housing.

Originally Posted by alxdgr8 View Post
Here's the starter cutout differences. You have to modify the bellhousing and not the rear timing cover:


And the solution:


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Old 03-12-2015, 03:09 PM
  #42  
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Doh, yes I had it backwards, you're correct. The answer both Spencer and I are interested in is yes this bellhousing you're working on could easily be modified to use with an 07K.
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Old 03-12-2015, 03:17 PM
  #43  
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How do you like your VEMS? I have one on the shelf for this and I'm really looking forward to hooking it up.

Last edited by Lapkritis; 03-12-2015 at 03:54 PM.
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Old 03-12-2015, 05:18 PM
  #44  
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Originally Posted by Lapkritis View Post


How do you like your VEMS? I have one on the shelf for this and I'm really looking forward to hooking it up.
It's still not on the car yet, still working on building a wiring harness for it. But, I've been in lots of cars running it and it's great. Really getting popular in the Audi I5 world.
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Old 03-12-2015, 05:47 PM
  #45  
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I've noticed that - helps that they have a plug and play solution for the earlier 5cyls. Makes it too easy!

http://www.efiexpress.com/catalog/

I'll be building the harness for this by hand... done a few hand built harnesses on megasquirt so old hat for me now.
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