Lightweight Turbo - TCup

So, how light can you make a 996 turbo? I've had a 996TT for around a year now and although I enjoyed the power, speed and comfort it always felt a bit heavy and I didn't really like the 4WD side of things either. So I decided to trim some fat, get rid of the 4WD, fit an LSD and turn it into a track rat instead. A few pics & details of where I'm up to.... 2004 X50 996 turbo with following mods: Exhaust Kline 200 cell exhaust Intercoolers DO88 intercoolers Turbos K24 standard turbos Tune 9E tune (540 bhp) FPR 5 bar press reg Wastegate 1 bar actuators Clutch 890nm clutch & release bearing Suspension Tractive suspension Brakes Giro 350mm discs track pads, GT3 gen 2 front calipers List of jobs ( Phase 1 ): 2WD conversion LSD (Wavetrac) Electric steering pump & rack rebuild PS pump delete GT2 slave setup AC delete Half Cage / Harnesses Lightweight Battery Rear wiper delete Lightweight seats Interior full strip Carpet / Centre console / rear seats sound deadening delete CD stack / Subwoofer / Speakers delete Airbag delete Lightweight door cards Cup steering wheel List of jobs (Phase 2): Lightweight bonnet Sunroof delete Full welded cage Lightweight front wings Lightweight engine lid Placcy windows Lightweight doors PSM delete Strip loom down to bare bones Then start drilling holes in stuff Etc etc

Some bits n bobs.... I did fit some GT3 buckets but they were too nice for what I was going to use the car for so that plan has evolved - they did look great tho.... Apex Apex VS-5RS 18x9 & 18x12

that is quite impressive did you by change have a pre and post car weight ?

Front end strip down part 1 before and after: Interior before and after part 1 (rear seats already removed in the before pics) Centre console slimline version: All airbags and speakers deleted: @Alex shifter fitted with spacers on housing and handbrake Scores on the doors as purchased vs now: 141 kg lighter so far with the initial interior strip.

Next onto the back end... AC compressor out. Found a 997 cup pulley to re-route belt to delete AC and PAS pump Conti belt that should do the trick: got some Nankang CR-S tyres on order: Gearbox out next so I can do a GT2 conversion on the clutch slave and fork and fit the LSD Then I can bin off all the 4WD stuff (prop shaft / front diff and front driveshafts etc). I should be somewhere around row 31 once all that is done....

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Yup tracking weight quite carefully, lots more to do and stuff to strip but car already feels more alive . Really looking forward to the 2WD and LSD swap then time to hit the track and have some fun.

nicely done,

That’s some weight saving and it must make a big difference in the way it drives not having all that extra weight to carry around. Those seats do look bloody brilliant and I’m liking the wheels…..have you a photo with them on your car?

Love it - it’s always annoyed me how heavy my 996T feels compared to my old 3.4C2!

looks incredible- have you thought about an antigravity battery? i have no idea if theyre any good but supposed to be a lot lighter..............

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Thanks Yes it’s amazing what all the easy to remove stuff adds up to, the 4wd parts are another 45kg which will soon be gone too so that plus the drag of the system should make a difference to weight and feel. No pics of wheels yet, need tyres so leaving the hollow spokes on for now. Cheers, yes same here. The boost was amusing for a bit but it’s too fast for the road if you really get on it and would be too heavy for the track so only one answer……a TCup! Yes they are great but also £££. I’ll start off with a less expensive lightweight battery and upgrade once funds recover.

Excellent, adding lightness is the easiest way to tune a car. I can feel the weight of a 60kg passenger (the wife) in my cars, so losing a couple of hundred kg is going to be huge. I'll keep an eye on this and report back with the weight of my build, we've got the same shell and a lot of the same gear, I'm hoping to lose some serious weight.

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Interesting - what are you building? In other news I found a set of genuine Recaro Pro Racer SPG Porsche 996 RSR seats for a more track focussed period correct look... Snug but very supportive - need to sort out some seat base cushions and sell the leather GT3 seats.

this will be a thread to watch

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Thread 'New build 996 RS recreation Project' 26 Jul 2024 I'm not sure if this is the right section for a project thread and it won't be a fast moving thread as it's not me doing the work and I'm away with work a lot. I currently have a 1989 930, but I wanted a custom build and almost bought a 964 to go down that well trodden pathway, but I talked to my old school mate at MLR Porsche (Marc Clowes) and he's going to build me one of their bespoke RS cars on a 996 platform. The ones he's built so far are incredible, they're individually numbered and look stunning, so I signed up. It's going to take around a year to complete, the shell is stripped... Harryblue Replies: 623 Forum: Porsche 911 996 (1997-2005)

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Ah-ha yes of course - I wondered if you had a TT project on the go too. The blue car looks amazing - mine will not be that pretty

Blimey you're not holding back..very brave although you can refit it all if you want. I bet it'll be a weapon on the track , basically a GT2 without an interior. Will you make up some lightweight door cards? I'd want some sort of soft interior I think. 400hp/tonne !! that's insane , I remember in the 80's if a car was 100hp/t it was rapid.

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Ha! No turning back now in my mind - I have everything neatly removed tagged and bagged so in theory it could all go back on but more permanent changes are going to occur soon so it is becoming increasingly unlikely. It was already fairly rapid at full fat 4WD with 550 (347/ton) so will be super exciting 2WD at 400+/ton. Then when I get bored I'll lob some hybrid turbos on it and then things get really interesting.

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I’d love one but I think I’m done with projects now. A GT2 evocation would definitely be on my list if I was going to do another. The sky is the limit in terms of power.

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You can't have too many projects I do like the GT2 but I've decided against trying to recreate one as unless you go all-in and get them just right they can look a bit odd (IMO) Tempted with a ducktail for bombing around and weight saving but will also add a big-ol wing too just for shits and giggles.

I had two DC2 ITRs - one stripped out completely by me, with SPG copy seats, taking about 80 kilos out of it, then at the same time bought an ex-racing DC2 ITR and you could feel the weight difference the full cage made , albeit you could also notice how much stiffer the car was and as a result much better turn in and faster round a corner! I'm not sure I have the balls (and getting too old haha) to strip my turbo out, but you're an inspiration here - just adding some decent seats makes a huge difference to any road car Are you going to add a GT3 half-cage? Not sure they do anything for stiffness but they will help when you are upside down, now your turbo is even faster than standard

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Yes I'll do a T45 lightweight half cage for phase 1 so I have a bit of protection and a good solid harness bar mount. Not a fan of the tech equipment cage so I'll swerve that. Then once Ive got it dialied in a bit on track I'll cut the sunroof roof out over the winter and maybe get a proper cage welded in with a carbon roof and doors to offset some of the full cage weight. Done plenty track time in all sorts of 911 over the years but this is one of my fave (customer) cars which has been a race car since 1998 and has a full proper FIA cage which really does make a difference so I'm keen to do the same in the tt at some point - we'll see. Getting the front discs to glow orange on the 3.2 race car at the Oulton RS day - such a cool machine.

What gearbox is that car running? Edit the yellow car

That's a good point, and I'd certainly be looking at the ratios in my turbo box as well - I think it needs a much taller first gear to help with low-speed driveability - not sure what the options are from cup gear sets, but then splitting a gearbox is never cheap, never mind these ones ... I appreciate the power delivery was quite different, but my Honda had a full race gear set in it and first (which had no detent) was good for 60 - made a huge difference on track, and I preferred it around town as well, recognising that I might struggle up a 1:2 incline standing start I'd certainly have a lower final drive in the turbo if nothing else

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Standard ratio 915 with LSD and Wevo shifter. Engine is standard 3.2 apart from 964 cams and a remap. I'm sure I'll be into the box at some point but apart from fitting LSD I'm going to leave ratios and final drive standard for now. It has no problem packing on the speed and with less weight and drivetrain loss should be even better than when I started. The Porsche 996 Turbo vs GT2 gear ratios - identical apart from the steel synchro on 3rd to 5th. TT Gear ratios: 1st gear: 3.82 2nd gear: 2.05 3rd gear: 1.41 4th gear: 1.12 5th gear: 0.92 6th gear: 0.75 Ring and pinion: 3.44 GT2 Gear ratios: 1st gear: 3.82 2nd gear: 2.05 3rd gear: 1.41 (steel synchro) 4th gear: 1.12 (steel synchro) 5th gear: 0.92 (steel synchro) 6th gear: 0.75 Ring and pinion: 3.44 GT2 sure looks like a fun ride.... Had a big win with todays weight saving efforts..... Fuel cooler module now redundant due to AC delete. so replaced with a simple bridging connector... Total saving of 292 grams A significant saving but dwarfed by the gargantuan weight of the door sill trims... Pleasantly surprised to find no rust under the trim (AKA water traps) - RESULT!!

That Gt2 film is one of my YT favourites..there's another with a modern 911 up his ass , you get the odd glimpse of the 992 Turbo S in his mirror I was amazed how much the rear seat backs weighed , I think it was like 4kg for the pair. 2kg for the AC Compressor.

That is as fast as ive seen a 915 swap cogs. I was convinced it was a G50 it was that quick

Great build keep us posted

Tell me more about the Apex wheels? I’d like to run wider front tyres and was looking at997 cup wheels, but would need a centre lock conversion too. What offsets have you gone for? TIA

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I haven fitted them yet but they see like a really nice product. I used their shop by vehicle along with other research on RL to see what people were getting away with. https://apexwheels.com/vehicles/porsche/911/996-carrera-4s-turbo Then once you select a wheel they have a gallery showing different car / wheel combos: https://apexwheels.com/vehicles/porsche/911/996-carrera-4s-turbo#vehicle-gallery It was this car that sealed the deal for me: A few detail pics - very nice finish and machining.

Thanks, did you buy in the UK or have them shipped?

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I bought them in the sale direct from Apex in the US around April, total cost was £2107 + £532 duty and they arrived in around 5 days from ordering. Buying in UK is pretty much double that.

Excellent write up Jevvy, thanks for taking the time to do this for us fellow 996 Turbo owners. Are you aware of a west-country lad with a lightened manual 996T? He's posted some videos on YouTube showing him sprinting his car at Castle Combe, and I think his weighs 1360 kg from memory, so it must be achievable. Your wheel post had me looking at Apex wheels on the web and I must say they are very impressively designed and tested. I'm currently in touch to get an up to date quotation from them with a view to purchasing a set for mine. My car is pretty good on track but could do with more front tyre width for sure, the 225 section limits the ultimate grip from the front axle which can be very frustrating at times. One upgrade that is worth it's weight in gold is to fit 996/7 Cup rear toe arms - these have been a revelation on my car, both on road and track, along with replacing every single suspension component. The car just feels much more planted now than it did prior to this change, which is allowing me to get the most from the Nitron R3 suspension that I have fitted (top notch kit btw). I'm very much looking forward to your journey - these 996 turbos have huge potential when lightened! Keep us all posted. Mike.

Any further updates on this?

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Nothing significant, been collecting some parts and getting ready to do the 2WD conversion, electric PAS pump swap, GT2 clutch slave and a LSD instal which I dont want to start until I have all the ducks lined up. Might run it without LSD first just for shits and giggles - I'm sure a one wheel drive turbo should be quite entertaining

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It's the 997 GT2 gearbox you want. Much stronger and better ratios, direct swap for the 996T box, bar all the clutch parts mind. 1st gear 3.15 2nd gear 1.89 3rd gear 1.40 4th gear 1.09 5th gear 0.89 6th gear 0.73 Final drive 3.44

Ceramic brakes are a huge weight saving. And you'll really need 6 pots for a track car. Add the 997 turbo gearbox cover with the integrated brake cooler ducts and secondary ducts. Rear brakes take a lot of stick with the EBD. Coilovers are a must. Go GT2 uprights too. Can remove inner bumpers too. Probably a fair bit of wiring if removing stereo and various options, trace it all back. I would keep door windows glass though, will be hot without AC.

Need to do a secondary air delete too and simplify the vac lines. Turbo wing mirrors have all the motors and options, get some billy basic ones.

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Thanks - I have searches setup for a 997 box so if ones comes up at the right price I will grab it. Ceramic would be nice but ££££, already on 6 pots so thats sorted (for now) I have Tractive kit fitted and I'm going to up the spring rate a bit and see how they go - I suspect if I develop it much further I will be using something different longer term. GT2 uprights would be lovely but I'm not trying to set laptimes or win races just build a nice fun track car for me and the mrs to enjoy - never say never tho!! Deffo going to trim the loom and I have a load of other stuff planned to get rid of dead weight but that will be phase 2, want to not get too carried away and get it on track first to shake it down and see where I'm at. AC - I drive faster when I'm hot Thanks - also on my radar but again more of a phase 2 thing. Do you have a track TT? Any links to build or info on your car?

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Built mine as a road car, so i have an OEM plus interior, barely a plastic surface left. Engine is a built 4.0 on syvecs, XR980 xona rotas, map switching through the headunit. AC intact. 997GT2 box, with all GT2 clutch items. You'll need the uprated helper spring! Everything else is GT2, PCCB's, uprights, sway bars, etc. Got a carbon roof to go on too, probably a winter job. I do have a build thread, but it's way out of date! Look up fearnsport 4.0 build or something. There was a 997 GT2 box on racecarsdirect not long ago.

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Posted below for future readers. Thread 'Fearnsport 996 Turbo build' 10 Aug 2017 Got my engine at fearnsport for a rebuild, Matt really knows his stuff I have to say, though I wish I'd gone to him sooner. sim996 Replies: 140 Forum: Porsche 911 996 (1997-2005) Will read now thanks.

Mine was on similar journey…

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Very nice - great colour! What roll bar did you fit? What power are you running?

PTS Nogaro Blue Porsche OEM A safe 600..

Mini update on a few small items.... Bought a T45 SW roll / harness bar from a fellow 911 UK'er that by chance matches my new wheels... Bought and fitted some semi solid engine mounts... Hollow GT3 adjustable front ARB for when I go 2WD Talking of 2WD....I bought another small thing to help with that....a 996.2 GT3 gearbox!! Ratio comparison between GT2, GT3 and TT (GT2 and TT are the same, GT3 a little shorter) Speeds in gear - solid line TT, dotted line GT3. I'm glad it wont do 200mph any more as I'm daft enough to see if it would Will give away a bit of top speed but will get there quicker plus it has oil cooler, spraybar, steel synchros, already setup for GT2 stle slave and no redundant 4WD output. A few more bits to collect before the big ol switcherooo. Hoping to be around 1350kg after this next phase then 1280kg the following year when I throw some plastic panels at it.

That gearbox is a nice upgrade, you’re going to hand a fun car! Good job.

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The eagle has landed…all gears slot in, no funny noises and stiff diff. Fingers crossed