Noahs944

First step for me today was building a turbo mount using the supplied manifold flange. This is what drives the turbo with exhaust gas. Unfortunately the flange is not threaded, which means bulkier mounting because external nuts.



I used 2 1/2" exhaust pipe with enlarged ends. I had to "shrink" the ends to fit the flange as closely as possible with vise grips after turning the round tube square with a hammer & a bench vise.

V2Rocket

nice...git r dun.

tack weld the nuts to the back of that pipe/flange.

Noahs944

Fit the hot air intake filter & used a hacksaw & file to cut the angle of the 2.5" elbow... very little margin for error!!

Think about it: hood clearance, brake booster clearance, master cylinder clearance, charge air cooler in relation to angle-of compressor housing , air filter clearance, oil in & oil drain, plus accessibility to additional bracket mounting for the heavy turbo! That's a lot!! Imagine if we had to run coolant in and out hoses also!!

V2Rocket

holy **** you work fast.

fwb42

Noah, You've got some great fabrication skills! I've got to ask what you do for a living?

Noahs944

Thanks guys! Every dog has his day...

fwb42-slowly skills are developing and tools being collected-which helps a lot!
I work as a heavy duty truck (diesel) mechanic. My dream has always been to do work like Ron Fournier:
https://www.youtube.com/watch?v=uihrzwKbUPs

Noahs944

Started on the turbo mount to the engine using the old sachs strut insert tubes that are just over 1" diameter, then welding washers on the engine side.

Noahs944

Callaway greatness!! Before the 951 was a car.

odonnell

You're making it look too easy! The dogma is supposed to be that the only way to turbo a 944 is to sell it and buy a 951...

porscharu

Did you run a continuous bead on the ID of the flange/pipe?

Jfrahm

Keep a sharp eye for any little ***** of weld that'll want to go through the turbo, particularly after heat cycles crack them off.

Noahs944

Noahs944

Sorry for the crap pics but here's the beginning of the turbo mounting bracket. It was made to mount on 3 oem bolts (one bolt each on the balance shaft cover, the alt bracket & the engine to frame mount).

Dunno where to go from here, but thinking maybe the exhaust flange (post turbo).

Noahs944

Thank you. Still far from the completion stage though, so maybe those guys are correct afterall!

Noahs944

Very good point! I hope to remember to thoroughly clean out all the piping before first start up