924Board.org

dwak · Joined: 03 Nov 2002 Posts: 839 Location: Eastern Ontario

I'm just about to install the 944 intercooler but all the photos I've seen show the rad support/fender brace cut all to hell.
Doesn't this greatly weaken the car structurally and what additional bracing are like minded people out there doing?

dwak

81turbo · Joined: 03 Nov 2002 Posts: 1065 Location: Oakland, CA

You could always have that section cut out of a 951 and weld in the place of yours. Otherwise my best advice is don't hit anything with the front of your car.

Fast924Turbo · Joined: 02 Nov 2002 Posts: 122

Hi Dwak,

Here's the stock 944 cooler built for the 944 Turbo engine bay. And it's the same chassis as ours. Below it are two modified 944 coolers:

The stock cooler is top, Stage 1, middle, and Stage 2, bottom. So they've improved the 944 cooler with 18% better flow by just adjusting the end caps with Stage 1. Stage 2 is still the same core, but with modified end caps. Now imagine if you can do even better, and I think you can, with slightly different end caps that better fit the 931 Turbo outlet hose placement. Remember, our turbo is placed WAY differently than the 944 turbo, so why keep the same angles?

Consider that in the picture above, there is an acute angle. However, in OUR cars, I don't think we NEED so acute an angle. I think you're asking absolutely the right question, but before you build it the way others have built it, let me plant a seed in your head for a second.

Is the 944 Turbo cooler the best placement and setup?

Here's just a side note for you to mull over and maybe consider BEFORE cutting to suit a STOCK cooler: Consider getting different end caps for the cooler and have them welded on BEFORE the cutting begins. All the 944 turbo AFTERMARKET enhancements for the intercooler, where they've IMPROVED the 944 cooler, have different end caps for better flow - but it's the same core! So I might as well plant that thought in your head now before you go ahead and cut anything.

Can you lessen the acuteness of any angle by 10 degrees? 20 degrees?

Apparently, each 90 degree angle is equivalent to adding literally YARDS of piping. If you can cut and create the cooler placement (with the right end caps) so you may be able to AVOID these right angles, your flow increases incredibly.

Here's something else to think about too:

http://www.designengineering.com/cryo2_related_items.html

BTW: I know the 'standard' tactic is to plop in the 944 Turbo intercooler

. But even the 944 boys are figuring out ways to do better than Porsche for intercooler design and placement.

dwak · Joined: 03 Nov 2002 Posts: 839 Location: Eastern Ontario

I think what impresses me about the 944 cooler is it's heat sink qualities which seems to be a big plus at low speed and idling.
Rick, take a look at my question below, didn't you replace that part? Aus Pete's used intercooler article made me re-think about my Supra light weight cooler.

dwak

924RACR · Posted: Tue Dec 03, 2002 1:41 am Post subject:

I don't think the upper rad area is that much of a structural piece, really. I'm not too concerned about cutting it up, though I still have no idea when I'll get around to installing one. The car is still very uncooperative about getting running.
_________________
Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

Eturbo924 · Joined: 09 Nov 2002 Posts: 2212 Location: Londonderry NH

Check this site out. Says it has a radiator and intercooler that bolts right in to 931. No chassis cuting.

"Intercooler - The intercooler is simpler than a charge cooler in that it is merely an air-to-air radiator situated between the turbo and the throttle body, usually located in the front of the car to maximise the cooling airflow. Unfortunately the 931 has no space to get the pipework past the standard radiator, so our system includes a replacement high-output aluminium radiator and intercooler to fit into the existing bodywork without modification. Available exclusively from 930 Motorsport.."Tuning Guide for the 924 Turbo (931)

930 Motorsport, Unit 23, Bank Quay Trading Estate, Warrington, WA1 1PJ
Tel 07000 930930 or +44 (0)1925 242342
Fax +44(0)1925 417638

Email: cdb930930@aol.com
www.930motorsport.co.uk

See some ideas here. http://www.cd-sales.co.uk/html/tuning931.htm
_________________
1982 924
1992 968
2003 C4S
Parts Parts Parts and More parts.
E-mail me for parts you need!
Drive Fast!

Joes924Racer · Posted: Tue Jan 28, 2003 1:55 am Post subject:

Monster Garage rocks.

juno · Posted: Wed Jun 09, 2004 2:05 am Post subject: Re: Ideas

Lizard · Posted: Wed Jun 09, 2004 3:00 pm Post subject:

I would recommend getting the rad support out of a 951, and also the front piece between the 2 frame rails, and the weld it into yours, that would be the proper way to do it, however with the 931, the where the alt is positioned and the fuel dizzy to make the front mount air air IC effective you would have to convert to EFI to loose the fuel dizzy and gain room there, just to go slightly off topic here, on this page http://www.924.org/projects/projectLJ.htm there is a pic 2/3 of the way down

showing this brace, and in order to answer the question on the page which is "why this brace/piece/tube is on the 931's frame?" the answer is, the fuel dizzy sits right above it and in the event of a MAJOR front end collision this tube bents up pushing the fuel dizzy into the hood and ABOVE the engine, w/o this tube here the fuel dizzy gets pushed straight into a possible red hot exhaust manifold. but back onto the post, and the Alt would have to be moved down to the location of where the AC compressor (for those of you that still have it) is. and then there would be enough room for the tubing, I would also think that in this instance you may consider creating a seperate oil supply for the turbo to keep the stuff the engine produces out of the turbo (this will increase the turbos life) with an electric pump to circulate the oil, and you also should be able to find another K26 gen turbo with a different intake compression housing with angles better suited to the IC install. however you may have to install an aftermarket BOV/POV in a different location as you would probably loose it with the change of compressor housing.
_________________
3 928s,

u000533 · Joined: 30 Sep 2003 Posts: 17 Location: Bristol, UK

Hi, check out this site for some great shots of a 944T with the intercooler out, http://www.cannell.co.uk/944%20Turbo%20-%2018.htm.

I've had to replace the panel behind the badge panel on my 924T and I'd say that the strength is in the chassis rails as thats what the bumper is attached to. On the 944T the sloping panel behind the badge panel is removed to allow space for the intercooler and there are larger holes in the bonnet support bracket to allow for the pipe runs.

The photos on the 944 site show it in detail, the black panel you can see in the intercooler space is a scoop to draw air into the cooler, which you wouldnt need if you have a 924 4 slot badge panel.

regards

Mike.
_________________
1981 931 turbo - sadly sold

juno · Posted: Thu Jun 10, 2004 10:34 pm Post subject:

Here's a company that sells the modified intercoolers above. Their stage 1 is £249 plus a 951 core though.
_________________
1980 924 Turbo RHD. 3" > 2.5" Stainless straight-through exhaust.

bigredtruck69 · Joined: 18 Oct 2007 Posts: 17 Location: Preston England

vexed73 · Joined: 05 Oct 2007 Posts: 187 Location: EASTERN, nc.