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-Build Thread- 997.2TT PDK by Esmotor

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Old 11-17-2016, 08:23 AM
  #1
3llooi
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Default -Build Thread- 997.2TT PDK by Esmotor

Hello all!!

I have always enjoyed reading build threads!

stay tuned for this one I want to give back to the community that I benefited from so much:

997.2TT PDK

Mods so far:
drop in BMC air filter
Speedtech 3" catless and mufflerless Exhaust
tune by Emre @ESmotor on 109 race fuel


car did 60 to 130mph in 6.8s ! I was impressed and asked for more


today I have received the following from Emre


1. do88 intercooler, Ypipe and inletpipes kit
2. IPD plenum
3. ESmotor custom headers
4. Aquamist meth kit
5. Cobb 3 bar MAP sensors
6. Forge DVs
7. DSC PASM module


I will be doing the build at home in the coming days and will be updating the thread accordingly


objective: fast, reliable and fun car for the street, a bit of track and roll racing



----on order:
1. PDK tune
2. a set of 19" BBS FI







ESmotor headers
do88 BigPack

http://www.do88.se/en/artiklar/bigpa...972-turbo.html





Progress update#1

Ok
so today I was just warming up .

I'll post few pictures and observations . later on I will update and format properly .


what's done:

1. removed bumper
2. removed airbox
3. removed Ypipe
4. removed throttle body
5. removed plenum
6. removed passenger side exhaust headers

7. installed passenger side headers: this side is the easy side due to the shape of the exhaust turbo flange. one extra step I had to do is open the bolts of the oil line from the oil pan and turbo and the mounting . allow me to flex the oil line in order to rotate the OEM exhaust headers to be removed . then installed the new headers easily. they are exact fit
​​​​​
​​​​​

ESMOTOR PASSENGER side header
Plenum out
DVs unplugged
Breather unpluged


TB cleaning

IPD plenum silicone hose
WOW I didn't expect this difference in size!
I hope they sound better! I didn't hear any 997.2TT headers in person
Inverted torx for headers bolts
Flanges are 12mm nuts
Inverted torx bolts
Better results than wd40 lool
Driver side headers
Passenger side headers
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Old 11-17-2016, 10:06 AM
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El Dario Loco
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Subscribed! Damnn those are some shiny headers 😄👍🏻
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Old 11-18-2016, 12:33 PM
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Excellent build! Very nice to see you taking on the build yourself, it is a fantastic learning experience. If there is anything I can do to help with the build please feel free to reach out any time
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Old 11-18-2016, 08:06 PM
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Thank you John!

I appreciate the offer very much

I like to do the hobby myself.


Who needs sports loooool
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Old 11-18-2016, 08:40 PM
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Ok
so today I didn't touch anything that's performance related loool

i was thinking of a way to mount the methanol tank, pump and few extra power port and voltage meter to monitor the battery . plus a power socket for whatever need.... and a port to plug the battery maintainer .



so I came up with this:
A frunk aluminium mat!!





Test fitting

I'm very pleased with the results


It is also removable







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Old 11-18-2016, 09:50 PM
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Subscribed too!
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Old 11-19-2016, 04:01 PM
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Progress report #3 19Nov2016

I didn't have much time available to me.

so what I did today:

took out the intercoolers
and
cut and removed the turbo inlet pipes.







Damn that's tiny!!

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Old 11-21-2016, 07:49 PM
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Progress report number 4 , 21 Nov 2016

So today I wish I had more done, but none the less, few items crossed

1. I've foamed and cleaned the engine
2. replaced MAP sensor by the intake manifold
3. installed exhaust header on driver side... torqued both headers to 24 ft.lb

​​



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Old 11-21-2016, 07:52 PM
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What's the foam you used? Do you rinse it off or just spray on ?
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Old 11-21-2016, 08:34 PM
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Originally Posted by saabin View Post
What's the foam you used? Do you rinse it off or just spray on ?
Rinsed off.

it is this one:

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Old 11-22-2016, 01:13 PM
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Originally Posted by 3llooi View Post
Thank you John!

I appreciate the offer very much

I like to do the hobby myself.


Who needs sports loooool
My pleasure, anything for a fellow petrolhead haha. I had my fill of sports in high school/college, nowadays....seat tim seat time seat time

Awesome updates, keep them coming. Horrible how flat and restrictive those ducts are!
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Old 11-24-2016, 04:50 AM
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Progress report number 5 , 24 Nov 2016

ok.. so today I feel like I had enough done hehehehhhehehehhe
1. ran the methanol 6mm nylon hose fron trunk to engine bay
2. I made the cut on the pieces lower to the tail lights to fit the larger intercoolers, and gave them a small spray of bed liner in a can
3. fitted the do88 turbo inlet pipes! they were a pain in the back to fit. the only way I was able to do it is to lower the engine around 2 inches by unbolting the rear engine mounts AND spray the hoses with lots of silicone spray lube .
4. I've tried to fit the IPD plenum and failed ! got tired. if anyone has a DIY of fitting the plenum please shoot it.


















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Old 11-25-2016, 10:22 PM
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Progress report number 6 , 25 Nov 2016


ok, today I was determined to turn on the engine... which I did

what's accomplished:
1. fixed IPD plenum, I didn't see a peoper DIY for installing it... but I've figured a way that was super easy... just lube the silicone hoses and push them all the way on the plenum... then position it on the intake manifolds and slide them over... that's it!

2. installed do88 intercoolers, straight forward, just followed the provided instructions .

3. installed the Throttle body, do88 Ypipe and the rest of the silicone hoses from turbo to inter cooler and from intercooler to Ypipe.


















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Old 11-25-2016, 10:25 PM
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https://youtu.be/IrIsjKSmAQg
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Old 11-29-2016, 02:18 PM
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Progress report number 7, 29 Nov 2016

hey all!


I was quite busy with work lately so I didn't put much progress .

but I'm pleased . I've done the following today:

1. I've stripped the interior at the back plus the two B/C pillars panels. removed also the carpet on the driver side to prepare to take out the PDK TCU.
2. ran the FAV wire and flow sensing wire from the engine bay inside to the cabin
3. ran the pump control wire from the trunk at the front to the back seat area. the HFS4 controler will be mounted behind the rear passenger side speaker. it's a tip I've got from friends to be able to access it when needed by only removing the speaker.
4. started thinking about the position and arrangements of pump and tank at the trunk.







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