996 C2 Motor Build + Turbo

Currently building my 2000 996 C2 engine and going with a single turbo setup. Below is my build sheet of what I plan to have done here in the next 2 months: TPC Racing turbo kit 3.4 engine getting iron ductile sleeves w/ 99mm bore 3.4 crank (weldup/grind stroke slightly longer than the 3.6 996 crank shaft) 3.6 pauter rods heads are getting 3 angle valve job with port and polish EBS springs Dual pump & Sugre tank fuel system for e85 single turbo HTA GT3794r ARP2000 Head Studs ARP2000 Main Bolts Arias Pistons Ceramic Coated tops, w/ molly coated skirts 9.0:1, 99mm camshaft (webcam custom grind) clutch (twin metalic disc aasco/tilton) Stock TB 74mm or do the ipd plenum with a 997 GT3 TB 82mm twin996s-1.jpg

170F2D18-964F-4DFF-822E-E116443A4544-695-00000069EDCE888E.jpg 1E647F56-20E6-4DEA-A974-808FBA44F38A-695-00000069E72A1563.jpg C61C2F65-5530-449C-92C2-D7F5761F2CC4-711-0000006B0920AE50.jpg

3E571BB0-DF74-402B-B299-F31CA5E3B941-127-00000006D9C194C1-1.jpg D8170E7D-DFCD-4220-827D-C3F49566C084-541-0000005BCDBE7359.jpg 75CBB349-ECD4-4763-8BF6-794BAE7C429C-1561-000000EE58727403.jpg

Wow awesome. Where are you getting the crank machined? Haven't heard of doing that before. How are you computing the expect compression rate? Also is that a narrow body car with turbo inlets?

Just ordered this Fuel System setup for e85 this weel along with alot of feet of aeroquip fuel hose and lots of AN fittings...lol

What kind of power are you shooting for? The GT3794r has a really large hotside for an engine like this, it's not even going to spool until 5k+ RPM, not to mention it's designed for high-boost applications (like 35+psi). Why not something more along the lines of a Precision 6062 or a plain-jane Disco Potato?

Where is the oil feed coming from for the turbo?

looks to be a solid build! nice and good luck

Halik, my engine builder is Jason at UFO but we have GEM doing the machine work on the cylinders and I don't recall the machine shop who is doing the crank but that is all they do is weld/grind crankshafts. I was looking for a 3.6 factory crank with the crank cage because it will work in my 3.4 but we ended up just measuring out another 3.6 stroke and and went just slightly longer with the new crank measurments. We are having to use the 3.6 length rods and we went with Pauter rods. The facotry pistons were scanned and we just adjusted the wrist pin height acordingly and are going with a 9.0:1 CR. BTY: i did not nor will not cut scoops since im running air-water IC.

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Step712.jpg RIGHT THERE : )

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The HTA GT37 shouldn't take till 5000k to spool or I'm screwed with that plan. Right now vivid racing uses a gt35r turbo at 5psi with decent gains over stock. Capt. I realy don't want to set a goal because I'll be mad and cry if I dont hit it... but I do want 500+ WHP But I will run about 1-1.2 bar to see what i can get. Todd Knighton will be doing my tune. The T4 60-1 turbo i have now will be maxed at 500hp and I want more than that

I love seeing threads like this where people are attempting something extraordinary with their cars. I know the easiest thing to do is sell your car and buy a turbo. But why not turbo your existing car if you have the funds, time, and energy? Hope it all works for you, make sure to let us see the finished product!

to be honest I feel like i just hit copy and paste with alot of the trial and error that some other forum guys have already done. I am just glad that the people on these forums are open to share helpful information with one another. The fuel system that I went with is already in play with two NY guys (m3ntal & prodigymb) from the 6speed forum. I was already set on going with iron sleeves but changed my mind when i saw Bisi's 996 3.4 engine that had the Golden Eagle sleeves that were a semi open deck that was designed not to sink or walk in the block under high boost. He has a twin turbo setup on a built m96 3.4 NA engine that is pushing 771whp at 14psi with VP 100 blue.

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I'm just surprised by the turbo choice for this type of build. A 94mm exducer wheel is HUGE, especially for a 3.4L engine. I mean, my 6.0 Powerstroke only has an ~82mm exducer diameter (a GT3782v, to be precise) and it has 18:1 compression on top of that. Seems you're going to sacrifice a lot of low-end usable power for the sake of making a big overall number. But I'm just some guy on the internet, I'm sure the guys doing the work on your engine know more than I do.

Todd K's tuning it. Can't beat that.

Did you consider Vivids kit first? I dont agree with leaving the CR high and lowering the boost like their kit does. I was glad to see someone do it right by lowering CR closer to what a gasoline engine should be for turbo charging. I dont see how your going to be 500 RWHP unless your considering nitrous. Great build and please post some more pics.

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Thanks! That the dead end, where the oil pressure sender would go on the other head, right? This is a tested location and it won't pull too much oil away from the cams? I'm only asking this because I have a Vortech V2 that was planning on grafting onto mine but couldn't find any info on the oil feed for it.

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Its big, theres no argument there. The hta gt37944 is actualy a 6766 if you go by thoes measurments. Its a 67.5mm inducer and 94mm exducer hot side the t4 60-1 is a 64.5mm inducer 75mm exducer w/ a 1.00ar hot side. the hta gt3788r is sized out as a 6466. I'm still up in the air, but it will be one of the two HTA gt3794r or gt3788r. I'm always open to any ones opinions and advice but high hp C2 single turbo projects are pretty much unsailed waters so its just trial and error (hopfuly more try less error)

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you may also look into canton racing. I heard that they have an adapter that goes between the motor and oil filter that alows you to add an oil feed for an accusump so it should work for turbo oil feed. Just not 100% sure. The location that you see is a tested location, this is where TPC runs it on all the turbo kits. I'm sure there are other ways to do it, but i'll run mine from the same spot.

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I did consider Vivids kit because of two things, air/air intercooler and 2nd was looks But before vivid built there own turbo system the TPC Racing kit was all that they were pushing. The other issue with the vivid kit was that they frowned upon doing a self install and realy sugested that if they sold the kit it had to be installed by them. Nothing wrong with that, but it just seemed like it was a more difficult install. The next reason for my choice in a TPC Racing kit is that Michael from TPC and Todd Kinghton have worked together and have developed tunes for diffrent setups on the 996 C2 that work. TPC Racing also did a 3.7 cayman build running .7 bar (10psi) and got 515whp with 10:1 cr on pump fuel. I ran a very very un scientific calculator to figure out psi and lbs per min of flow and it will not be hard to get 500whp. See Below: [IMG] [/IMG]

Do you have any idea when you will be finished? Good luck on your project.

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it was supose to be done now....lol My only hold back now is the pistons, so they should be done by the 2nd week of the new year. then about 2-3wks to put it all back together and in the car and about another week for tune, data loging and fine tune again. I want it done for TX2K13 which is in march.

Where is the shop located doing the work? I live in SAT also and need a shop to do some work for me.

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You'r comparing a diesel engine turbo to gasoline engine turbo. So i'll bet that the guy's that are building this engine know's more than you At least on turbo charging.....

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I was using it as a broad comparison, don't try to tell me what I do and don't know.

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Long Beach, CA..... lol There are no people is san antonio that I know of that can tear down a watercooler Porsche engine and put it back together. Doesn't mean that there arent any I just don't know who can. But there are a couple people in Austin, Houston and Dallas.

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here we go... Don't get all Ron Burgandy in my thread lol j/p

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I hear Bob Jones Autowerkes is supposed to be good. I was told he has been servicing and racing Porsches for over thirty years.

i don't think he will tear down a water cooled engine but i could be wrong. I've heard about him for tons of air cooled stuff though and he does alot of thoese rebuilds. Boost Logic out of Austin did Powell's 996TT build, Akram (formerly out of mwhouston) did robmds Bluesy 996tt with help from protomotive i belive what are you needing to do to your 996?

Questions on the Golden Eagle sleeves...........What are they made of and rough cost ? You definately have a fun project underway and thanks for sharing . Dave

they are ductile iron sleeves. ironicaly they are not realy sleeves /liners because they remove the whole factory cylinder and replace it with these new cylinders. I went with them over the LA sleeves because they had a better way prevent the cylinders from walking under higher boost with that integraded semi closed deck design and they step the bottoms into the block to prevent sinking as sleeve. I'll pm you a round about cost.

The approach makes sense with a talented machine shop .Are you the first or have they done this before ? Dave

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Nope, there are others among us one is making 770+ whp with a twin 6162 turbos thats clames of made right around 1000 with larger turbos but with awful lag. GEM guarantees the sleeves not to crack up to 1500hp and guarantees them never to sink. So thats fixes one problem, the rods are a 4340 chrome moly forging, x beam with arp2000 bolts. my fears will be detonation, and how high i can take the manifold pressure and well if factory head gaskets will hold. the e85 fuel whill help dramaticaly with detonation since it has a rate octane of 110 which is 2.85ga vs 9.00-16.00vp race fuel and my gas stations nearby me carry e85. the ceramic coated piston tops will also help reduce any hot spots on the pistons to help reduce detonation. The head gaskets are factory but from porsche there pretty nice and triple layered. The arp2000 head studs will help but it may be trial and error to see what can take. The other security measure is the copper oring gasket that were going to run on the cylinders.

it seems to be working for 1000+ hp GTR's lol not that I am comparing the two but here is a picture a a r35 block with similar sleeves/cylinders, theses are MID darton versions

Who will be tunning it and how?

Can you pm me a cost as well?

Impressive and well thought out .Since others have done it appears the heads can handle the increased loads and partial decking .Does the builder do anything special to the heads ?I know they crack -mine did and it was not water pump related .

Todd Kinighton at Protomotive is going to be doing the tune. I should be getting my injectors that he recomended for my e-85 setup from his this comming week. trendy996 - I was pretty vauge with pricing as I am not not one who charges and its all being done through my builder. But GEM charges between 1500-2000plus for just sleeving; BUT you can have them order up custom pistons and have them do a final bore, you can have them step deck it, and o-ring groves and so forth. Best bet is just call up Golden Eagle and get a quote or if you are not building your own engine have your builder call them up as he can provide more exact specs for what you want. dcdrechsel - my head cracked as well but it wasn't a water pump failure but it was because of of a hot spot that seems to be the problem on all of these cars. is aways a crack on the same exact spot. most times its a piece of the water pump impeller that creates a blockage and then the hotspot on the head which in turn leads to a cracked head. the 997 waterpump is an upgrade along with lower t-stat big key is replace the waterpump regularly

Ok, this engine is built by someone else and you are the customer?

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BINGO You don't want me building anything unless its with legos or construction paper LOL

just got my injectors from Todd Knighton 02445B61-BF0F-4C25-A890-62E4E7844B54-255-0000000E3EC796F6.jpg

Todd K. one of the only tuner I would consider....

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You should be able to spool that turbo quickly. The GT series is a very fast spooling turbo. Have you thought about thermal coating the exhaust prior to the turbo to help with the spool? I ran a GT35R82 on my 2.5L Subaru and it was fully spooled at 4200rpm and was beyond stock power levels on it's way up to being spooled. So a GT37 should be fine on a 3.4L. 500whp on e85 should be a walk in the park as well (I would expect far more). My security won't let me open the first page of the thread. What supporting mods are you running with the turbo? Changing cams? Headwork? What do you plan on doing for the trans? Or do think the M96.00 can handle the power?

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3.4 engine getting iron ductile sleeves w/ 99mm bore 3.4 crank (weldup/grind stroke slightly longer than the 3.6 996 crank shaft) (the two mods above bring my engine from 3.4 to 3.9) 3.6 pauter rods heads are getting 3 angle valve job with port and polish EBS springs Dual pump & Sugre tank fuel system for e85 single turbo HTA GT3794r ARP2000 Head Studs ARP2000 Main Bolts Arias Pistons Ceramic Coated tops, w/ molly coated skirts 9.0:1, 99mm camshaft (webcam custom grind) clutch (twin metalic disc aasco/tilton) Stock TB 74mm or do the ipd plenum with a 997 GT3 TB 82mm x51 intake manifolds

I like the precision billet wheel/air cooled/ball bearing turbos. I feel like they would be a better performer for the 3.4l

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As BiteEmNBeatEm mentioned Golden Eagle Sleeving utilize ductile iron sleeves which are strutted and brace to the cylinder block. We have had great success on several of our projects, including our 1976 Porsche 911 utilizing an M96 water cooled engine and as well Bisimoto's 2012 Honda Civic which produces over 1000whp on a 2.4L engine. For more information and best pricing, kindly give us a call. Here picture of Golden Eagle sleeves prior to final installation in a 4 cylinder engine.

Looks good Bisi, is this 4cyl going into a customers car or a personal car? By the way do you have any dyno graphs that you can e-mail me or share of your m96 engine that is in your awsome '76 911. That build that you did brought some faith back into the m96 block for me. What ever happed with running the Texas Mile, I had read some where that the blue '76 was built to run the Texas Mile. Do you have any sugestions for a single turbo size?

I will begine a build thread soon with exact details, and this week, I am upgrading to a water methanol kit, so the story of the m96 swap continues. My team and I have the very best suggestion on turbo sizing that you need...kindly share you goals, and driving style. In addition, this is 'Bisi, and BisimotoSales is Julio! Thanks.

Is it not more cost effective to sell your car for a 996tt? I'd love to see your end results.

Bismotoi , the car is being built for roll racing from 40/60mph roll, it by no means ment to be a daily driver but i would still like to maintain comfortable drivability for thoes weekend nights when me and the wife want to go out for dinner and a race...lol I don't have a set hp goal but I would love to get close to the hp levels that you are seeing form your twin setup. Todd Mckensie is doing up a set of heads for me soon so once we bench flow them we can come up with the most appropriate cam setup. We did however have a change in plans from running the 3.4 weld/regrind stroked crank , to just using the a 3.6 crank and crank carrier. this way we are working with a virgin crank so hopefuly the outcome will be better. we will also be sending out the main bearing to get coated and are ordering up a set of coated race rod bearings from ebs to help with gaining few more rpm's out of the engine. Were still up in the air about cross drilling the crank. I did take your adviced and idea of using the x51 intake manifold and luckly there were two left in the US : ) and there are 7 more in Germany...lol talk about a diminishing part... by the way did you order up the x51 lower intake runners as well or did you just use the pair of upper intake manifold halfs with the stock m96 lower intake runners were the injectors mount? which meth system are you going to run? (im guessing its AEM since your already running an aem standalone and aem throtle) I've looked into the alkycontrol, aquamist, snow and aem because i know with the air2water IC that heatsoak will lead to high intake temp. for me. A few of my friends are using meth inj with great sucess, they are are all 900-1200whp vettes but some have lowered intake temps dramaticly with there 50/50 methwather injections. Bisimoto, I also wanted to ask you if you used a oem porsche mutilayer head gasket with the copper oring or if you used a copper head gasket with the o-ring? The reason i ask is because the cometic and any other multilayer head gasket (oem porsche included) seemed to have mixed results with copper o-ringing but i have heard that if you used a copper gasket with the oring your cylinders will fail before the gasket...lol ...by the way what are your rpms at 771whp? speedyellow , it would of been more cost effective to probably just buy a high mile, good condition 996tt and keep it stock but then I would still be the guy with a stock 996tt : ) now i can be the guy with a far from stock 996 C2...lol

got the anti surge tank dual fuel system in today from Raduim Auto, and it looks great. I also had nothing better to do at 2am so i put it together DDD30EBE-6152-4C4E-B0C1-8EB46F26943E-124-000000165FF2C1F0.jpg 782BEF25-171D-42E8-B7F8-7D8515BD466A-124-00000015F75D9DE2.jpg

Roll Racing??? This is the first tims I'm hearimg about this. Details please.

Imo000, its just strait line runs from a rolling 60mph start, You Tube You Tube

You have a good point.... For a non-DIY it seems like it would cost more to build then just picking up a 996tt. Are you going to be able to put all that power down without big fat rear tires?

GREAT QUESTION.... but on a serious note I'm looking at 295/30/18 R888 or MT ETStreetII 305/30/18 I have set of HRE's in 19" but the will just stay the way they are with 305 street tires.

Not sure if 305s have been done on a Narrow body without rubbing. I foresee a little cutting of the rear fenders???

they work fine i have them on my current HRE 19" wheels. Its all in the offset. (NO CUTTING NEEDED) heck there are guys running 315's on NB 996s. this is a picture i took from another forum. this guy is running 315's on 18" wheels

Thanks for the heads on roll racing. Much easier on thendrivetrain than 1/4mile. I like it.

imoo000 you can check out videos on youtube just search "Texas Invitational" and you will be able to see some porsches racing from a rolling start. they are almost always at airfields but I know up north there was one on a 1/4mi track, just not a long enough strip to get to 60mph stage up to each other, race and then stop...lol

ended up going with a garrett GT4094r with 1.06 ar housing on a side note, that has nothing to do with my engine build, I also ordered up a set of Rottec sGT3 seats in carbon shells with alcantera/ all black cross stiched and a Agency Power Roll Bar in Silver

Can't wait to see finished product. Todd is a very good tuner!

Well its been a while since Ive updated this post but we had a few "hickups". Kind of my own fault but im glad it all worked out. We had to redesign some pistons but all the guess work was taken out when we sent in a set of heads to measure out the volume of cc in the heads and head gaskets and get the valve clearances so that the pistons work be exact on the C/R. In a way it would of been a heck of alot easier to just stick with a 3.4l 96mm piston because we could just scan that piston use the current stock c/r #'s to figure out the correct dish to get 9.0:1 but thats all behind me now. The car is now in CA with its powerplant and over the next few week it will get the fuel system installed and I will get the lsd and clutch all taken care off. I am still up in the air if i am going to change out the ring and pinion and go to a 3.00 ratio but im sure I will be making a decision soon. I did get my seats and roll bar so I was pretty excited about thoes so I will share some pictures even though they have nothing to do with the engine build : ) 9B19DF0C-7634-445A-BDC7-2C121DB96FFD-969-0000014368FC93AC_zpse8b4d879.jpg 7C424577-A687-431A-856C-E4A3E80F1039-969-0000014360EC7777_zpsdf2635aa.jpg 6B0DF3C6-B8CC-40E5-B248-DBFF7DF79A97-969-0000014377CBFDCA_zps0a743303.jpg 393E2183-8444-4522-B20D-882BB562AFF9-969-0000014370E1DC14_zps0570f6cc.jpg

I have the same roll bar in my C4S, I really like it.

yeah the Agency roll bar is pretty nice, i can wait to install in in the car once its all finished. Even though the cross & diagonal bars are removable I don't know how easy it will be to remove them once installed and i realy don't see the need although this was the selling point for me : )

pistons are now complete and finished from Arias. Now they need to go out for ceramic coated tops and moly coated skirts. 571873DA-1CCB-4D5C-A7CF-2B2F0CBC975F-2198-000001BEBF5BCDC0_zps878c869a.jpg 584EA911-8A17-49F6-AF29-EB701AF6D790-2198-000001BEB7737E8F_zpsde688fff.jpg 2CBB67A1-D4EA-4C41-B484-B97F0B6A1677-2198-000001BEC48D942E_zps186a700c.jpg

Arias can't provide a ready to drop in piston, you have to get the coatings done yourself?

They sure can and were using the same place for the coatings but we need to get them measured back to the block for the final bore and hone.

Not to be crude, but will you share with us the cost of this endevour

I'm afraid to add it all up because with how much is probably in this project I could have been posting on the "996tt forum". But to avoid, avoiding your question I think i realistically added up around 30k in this build. engine build, gem sleeving, pauter rods, arias pistons, coated bearings, arp headstuds, mainbolts, 3.6 crank and crank housing, x51 upper/lower manifilds, ipd plen, gt3 tb, heads, cams, valvejob, clutch, flywheel, lsd, tpc turbo kit(used), gt4094r turbo, hard pipe, injectors, surgetank fuel pumps, all new fuel line -8/-6 and all the an fittings and little bs crap here and there. But a whole lot less than the 80k plus that goes into these 1000hp+ 996tt builds. Heck if I can put down 700hp just bought each additional hp for $65 per pony...LOL

I cant wait to see dyno numbers!

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Embee Interesting finish on the side skirts.

This thread makes me happy in the pants.

We are looking forward to the completion of your project and I will shortly have some information to help you out! - Julio A. Bisimoto Tech.

With all of the engine work that you are doing to this car, you might want to have the gearbox gone through at the same time. If there are any existing issues internally already, they are bound to show their ugly head once you get this bad boy completed and back on the road. It would be a shame to have to pull the gearbox after all this work. Just a thought. Erik Johnson

Thanks Julio. Ya'lls M96 engine is what gave me my final boost of confidnce to try to go all out on this engine and maybe i will be as fortunate as you guys to have similar power gains. ""fingerscrossed"" Erik, I couldn't agree more. I'm just not a fan of the pressed gears on the g96/00 gear box and wish there was an easy way to fix it. If you have any ideas I would love to hear them. But I do need a lsd!! I'm leaning towards a helical vs a clutch style since i do not need the ajustability and i think my fulids will just stay much cleaner than a clutch/disc style lsd.

You have mail. Keep us posted on your build. It looks like it is going to be fantastic. Erik

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quit getting off to my thread, this is for me to get happy too..LOL yup sure is embee who is doing the coating. yeah, the skirts don't have the typical forging that you see like some of the other piston makers. Diffrent strokes for diffrent folks!! lol Thanks Erik

eric, do you know if oem # 950 332 083 01 LSD will fit the g96.00 gearbox?

Yep that LSD will fit into your G96.00 you will need to make a modification to the axle flanges perhaps, but the differential itself is the same. I would recommend not paying too much for a OEM unit, as they tend to require a bit more maintaining, but you can certainly have it installed. Happy to help, Erik Johnson

Well, not much progress since im just waiting for piston coatings. But I did have a chance to put together the wire-relay harness for the twin fuel pumps. 33ED1FEF-F866-4E47-B85A-6F2045AFD1B3-1791-0000011FBB62C51B_zps7ede1ffb.jpg

Pistons just got back from embee coatings and look great. So i figured I would share the engine p@rn with all of yall. I also got my order for a Tilton " twin disc " clutch squared away so I should have that in about a week along with the Aasco flywheel. 56b5744e-d090-4530-8dc3-6d1a671fccc9_zps79c35b78.jpg 5413dd32-e2a7-4819-b14a-328892bde282_zps8c17e113.jpg

Well it been about 3 months since I've updated my poor lil build. To be honest not much has realy changed but I did realize that I never posted pictures of my block with sleeves installed and grooved for o-rings. I am down to needing to port my heads, build a set of 4-cams, and coating a set of main bearings to get this block complete to put back in the car. 0dfe266f-f244-49a3-a31b-a3222f3d1384_zps1ce82d86.jpg porschesleeves_zps208164e7.jpg 058008bb-635a-4eec-ba1a-270ddf43cc19_zpsbc8909c7.jpg

Can you elaborate a bit on the bearing coating and the reason for it?

I don't see a tool counterbore on those pistons? It'll be fun installing 4-6 pistons without it. If you haven't gotten the turbo kit as of yet I have one with 300 miles on it that I no longer need. Its not even dirty and is complete from TPC.

Here is the rest of the fuel system. We should start assembling the engine here as soon as the coated main bearings come in. 26109CDA-8034-4B9D-95C1-EFDF988101F5-193-000000099D6949D5_zps15c9c517.jpg

so whatever happened to this?