My 87 944 Hybrid, LS1

I got a lot info from this forum for my 944 LS1 swap. So I think is time to share my project here, and be able also to provide some info for others.

I picked up a 87 944 earlier this year.

The car has some dings, nicks and scratches. The engine is running, but has a few oil leaks, and the water pump is leaking water.
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Already hammered out roughly a dent behind the rear wheel.

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The interior is worn beyond cleaning and TLC.

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The front seats will be replaced. The carpet has seen better days. I decided to start on the inside  first, since I don't like to sit and work in a mess.

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So I just went ahead and got rid of the carpet. Cleaned out the interior.

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I had a set of black carpet floating around, which I used.

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What a difference it makes.

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The rear seats look OK after I gave them a good scrubbing.

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While I had the rear side panels out, I checked the speakers and found them dead.

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I replaced the old Blaupunkt speakers with a set of Polk Audio I still had.

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So much for the inside. And now I can move the engine.

Started a bit disassembly

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That engine was leaking oil for a long time.

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Engine is coming out.

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There was a lot of oil from leaks combined with dirt.

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Getting it all cleaned up.

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More to come soon.

Cheers
Engelbert

Continue here with some cleaning.

Did I mention that this car was a mess ?

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Cleaning time.

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Front support cleaned up.

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Cleaned and plated some hardware.

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So now I got this 944 Turbo transmission at the right. The left one which came out of the 944 has a longer 5th gear. So I will swap them out.

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Did a little work on the brakes.

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The calipers looked pretty ugly.

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I took them apart and cleaned it all up.

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Here are they ready for assembly.

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Assembled and ready to go in.

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Rear end done.

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Front end also in. The sway bar is not yet installed, and I wait with that for better access.

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Got the power plant ready to go in to test fit.

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Looks like it's gonna fit.

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It looks like it belongs there.

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There is more space around than I expected. Wow. A lot more work to do.

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Cheers
Engelbert

Once I finally received the exhaust manifolds, I was able to do the exhaust system. It took about 3 months after ordering the exhaust manifolds until they actually arrived.

Most time on this project was wasted on waiting of parts, or try to figure out what's included in the package, and when it finally arrived it was always a surprise.

Anyway, enough wining.

I used a Magnaflow muffler 3" in and out.

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I coated the exhaust manifolds with Cerakote.

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2.5" from the manifolds to the Y-piece and 3" all the way back.

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The steering column goes between the 2 down pipes.

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Also got it started up for the first time.

Now I can start to sort all wiring and hoses out, finish up the brakes and clutch, and clean up the engine compartment.



More to come

Cheers
Engelbert

Very nice! We are getting started on our 944/LS1 swap. Engine bay is a lot uglier looking. What are you planning for a brake booster / pedal system?

I got the Mustang Hydoboost, using the Mustang MC, stock 944 pedal.

Cheers
Engelbert

That'll give you the incorrect brake bias. Best to use the Mustang hydroboost with the TPC adapter and 944 MC.

Here are some items to look for:

The Clutch:
When I got the clutch kit, and tried to install it, the center of the clutch disc hit the pilot bearing before it touched the flywheel. See images below.

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So it turned out that the clutch disc was wrong, and TPC sent me another clutch.

The correct disc is the right one in the picture. The center of the engine side has to be flush with the disc surface.

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After waiting again for TPC to figure out what happen, finally I got the correct disc, and the project could continue.

The Hydoboost system:
Once I got finally the hydroboost system, and opened the box, the was the hydroboost unit, assembled with the adapter plate, a bag of fittings, one roll of HP hose, and a roll of LP hose. You got to figure out how to put this puzzle together.

I asked my self: How many of these kits are sold ? And there is not instruction or anything that comes with it. The type of fitting was new to me, so I had to search how the fittings are correct installed to the hoses. Obviously every single LSX swap has a different way of routing the hoses to HB and.or PS.

Here are a few pictures what you get with the HB system:

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The pin which came with the HB was to short to reach all the way true, to install the locking pin. Also the rod of the HB was quite shorter as the 944 and the brake pedal sits now closer to the floor.

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I had to file the connection a bit and used a smaller pin.

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Here are a few pictures of the installation:

There are no studs welded on the adapter plate, which is actually a good thing. It would not be possible to install it to the firewall with studs, because of the cyl head.

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Connection to the steering rack.

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From there I routed the line to the back of the engine and up the the HB.

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From the HB to the PS pump.

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That's it for today, I will post more pictures soon.

Cheers
Engelbert

docwyte wrote:That'll give you the incorrect brake bias.  Best to use the Mustang hydroboost with the TPC adapter and 944 MC.

This is what everybody said, however, the brakes feel fine, and I didn't had the feeling, like going true the window when I hit the brakes. I must have done something wrong. Open of any inputs. I'm using 944 stock calipers.

Cheers
Engelbert

Wait till you get out on the race track. Then you'll understand. Heed my advice now or pay the price later. Been there, done that.

docwyte wrote:Wait till you get out on the race track.  Then you'll understand.  Heed my advice now or pay the price later.  Been there, done that.

It will be a daily driver, no race car.

BTW: How many are out there with the Mustang MC ?

Cheers
Engelbert

not that many now as it gives way to much rear bias.

the 944 uses a step bore master cylinder, meaning the front and rear chambers are different sizes. its a 15/16" bore for the front and 13/16" bore for the rear. the mustang master is 1 1/16" straight bore.

i punched the numbers into the brake calculator i have, the 944 n/a with single piston calipers is roughly 75% front 25% rear brake bias. this doesnt take into account the factory bias valve that limits the rear pressure, making it closer to 80% front on a hard stop. just tossing the mustang master cylinder in there puts your bias at 65% front 35% rear. what it all equates to is the car will likely stop ok in every day situations, however during spirited driving, or a panic stop you will likely lock the rear wheels up and toss the back end around.

Thank you !

That's great information. I will look into this, I'm not diving the car so much, and so far the brakes feel fine. I will do some tests with more aggressive braking and see what it does.

Thanks
Engelbert

Nice work and quality photo record!

Some additional info:

The Hydroboost had a leak, and I found the O-ring almost washed out, between the aluminum block and the bolt what holds the block the the unit. I replaced it with an aluminum seal ring.

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It looked OK for a while, until there was a small leak again, and this time it looked like as it comes from the area between the alu block and HB unit.

I removed it again, cleaned it all up, and replaced the inner O-rings with new, thicker ones. So far it looks OK.

Just something to look for.

Cheers
Engelbert

I just have a few pictures here, that will help some members who plan to do the conversion, but like to see what the parts look like, or what will show up when they order.

Here is the hydraulic throw out bearing, mounted to the adapter platewhich will mount to the Corvette bell housing, and connect to the Porsche 944 torque tube.

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The line at the left will connect to the clutch MC, and the line at the right is to bleed the air out the system, and gets mounted up at the fire wall for easy access.

In this picture you can see the torque tube mounted to the adapter plate. The bottom cover is still missing in the picture.

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Here is a picture that shows the vehicle speed sensor mounted at the left inner axle shaft.

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Here are some pictures from the front bottom of the engine.

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Fitting the GTS headlights with LED inserts.

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From Inside.

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Adding the finishing touches to the engine compartsment.

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Got the inside to a point that I like it.

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Still looks like a 944, LOL

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At night with Lights on.

Low Beam.
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High Beam.
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Cheers
Engelbert

Whoa! Those headlights are a dramatic improvement. Do they make something like that but with pop-up capability? With those headlights, a good stereo system, A/C and some bluetooth, this could be a killer DD!

jpkinerk wrote:Whoa! Those headlights are a dramatic improvement. Do they make something like that but with pop-up capability? With those headlights, a good stereo system, A/C and some bluetooth, this could be a killer DD!

you can get LED headlights that are round that are designed to replace a 7" round sealed beams. ive used the ones from DW Speaker Lighting a few times and they kickass. kind of expensive though.

jpkinerk wrote:Whoa! Those headlights are a dramatic improvement. Do they make something like that but with pop-up capability? With those headlights, a good stereo system, A/C and some bluetooth, this could be a killer DD!

Here is what the LEDs look like for the standard 944 headlights. They have 2 Low Beam projectors which stay on when switch to high beam.

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Check it out at [You must be registered and logged in to see this link.]

Cheers
Engelbert

Great documentation
Thanks for sharing

Sent from Topic'it App

Awesome documentation! Mine is a DD too, you will love it!

Andy

Hey man great build. I just got a 86 944 NA in mint shape but the engine is seized so im doing the LS swap. thanks so much for the pics and info

good looking car, good job on the build

Just in time for cold weather, I finished the A/C.

Made all custom lines. Now the car is complete to use for any weather. There are still some cosmetic little things to do, it never ends of course. LOL.

Here are some pictures:

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Cheers
Engelbert

I figured it would be helpful to see what such a conversion can cost. I have listed what I have spent just on parts, plus the tuning which has also some labor cost and a new throttle body included.

However, the cost of the car is not included. I'm sure there are ways to make this cheaper.

Here is a quick overview what such a conversion about runs:

449.00 Headers Custom Manifold style, Gasket and Bolts
219.99 Ceramic Coating - Manifold
24.99 C5 Bell Housing Flywheel Dust and Debrie Cover
359.99 C5 Adapter Plate
199.99 Hydraulic Slave ThrowOut Bearing with Hose / Fittings, Bleeder
399.99 TPC Stock Clutch, GM Pressure Plate, Flywheel, and ARP Bolts
79.99 Pilot Bearing Adapter with Bearing
279.99 Motor Mount uprights LS1 (pair)
79.99 1/2 Spacers
665.00 Oil Pan Kit for On Pan Filter
79.99 Heater control valve and hose kit
199.99 Fuel Kit  - Clamp Style. Stainless hose for engine bay.
579.00 Stand Alone Wiring Harness - LS1 - DBC - EVC Injectors
250.00 ECU programing
134.99 VSS Bracket & Sensor
43.99 Throttle cable
369.99 Air Conditioning
529.99 BRAKE INSTALL - HYDRO BOOST
117.46 Alternator - 4pin - Camaro
139.01 Alternator Bracket
139.01 Power Steering Pump - Camaro
139.01 Power Steering Bracket
16.86 Idler Pulley
30.94 Tensioners
87.91 Water Pump - Camaro
18.94 Water Pump Gasket - Camaro
82.67 Harmonic Balancer - Camaro
 7.51 Harmonic Balancer Bolt - Camaro
20.79 Serpetine Belt - Camaro
225.00 Used 951 radiator and fans.

5,971.97  So far.

Now you need an engine and a 951 transmission.

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3,300.00 for my engine, 2000 C5 Low milage
1,630.00 For the 951 transaxle, LSD and oil cooled.

4,930.00 Eng. and trans.

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10,901.97  So far.

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In addition to the above I spend the following:

346.50 wheel bearing, suspension parts
 45.25 Trans. End plug, seals.
 62.50 Gear oil, hoses. etc.
 50.52 New valve cover gaskets
 39.99 Clutch fluid res.
  9.85 Fuel hose
 12.59 Napa misc. parts
 24.98 exh. Gasket
 67.31 New spark plugs
 22.27 Reflective foil
  7.99 injector seals
 17.05 ECU shipping
 56.25 belt AC, heater hose
 15.14 sealing compound, glue, etc.
 98.16 Dash cap
 26.49 Paint
 66.60 Hatch seal
460.08 Exhaust system
 27.16 Wire for VSS
  6.27 AC switch
199.09 AC hoses and fittings
 25.21 Hose for hydoboost, original was bad.
 28.57 Temp sending unit
 80.00 Front Brake rotors, Bosch
 20.00 Rear caliper repair kit
 63.17 ignition wires
300.00 New 951 Axle shafts

2,178.99  for the above.

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12,710.97  so far

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In addition I replaced the front seats and the carpet, since they were trashed.

550.00 Front seats
200.00 Carpet

750.00 for the above

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13,460.97  so far

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 500.00 set of 18" OZ racing wheel
 200.00 rear tires

 700.00 for above

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14,160.97  so far.

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1,282.56  National speed Tuning parts and labor, Inc. new throttle body

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15,443.53   so far, and the car is not included, as well there is no labor included, since I did the work myself.

Cheers
Engelbert

Thanks for sharing expense details. Interesting. How are you doing with the sale? Yours is a beautiful car and I gotta believe you'll get lots of interest when spring rolls around.

As a comparison, my spread sheet shows $35k total invested including the original car and engine purchase. Lots of money for a result that's not worth near that much on the used market. However, I regularly catch and pass rigs at the track worth 3 times that much.

Rich