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Shaggy is Intercooled * * * UPDATE - PICS * * *
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11378
Location: PacNW

PostPosted: Fri Mar 21, 2008 11:34 am    Post subject: Shaggy is Intercooled * * * UPDATE - PICS * * * Reply with quote

I am too exhausted to post them now, but I have a ton of pics and the project is done. Just getting rid of the S1 TB and pressure ducting has the car idling and sounding better. . .



Rasta Stoked.
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Toofah King Bad

  • Red (1987 924S) - Pro44/Spec944


Last edited by Rasta Monsta on Sat Mar 22, 2008 4:38 pm; edited 1 time in total
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jazz guy  



Joined: 26 Nov 2002
Posts: 401
Location: Colorado

PostPosted: Fri Mar 21, 2008 11:56 am    Post subject: Reply with quote

If this were the Rennlist, I would have to say something like, "This thread is useless without pics!" But... being that this is the 924board, I'll be patient and extend a hearty, "Job well done!" instead.

I like the design of your IC, and I'll be quite interested to hear how it works. I bet it feels good to see some of your plans coming together.

Have a cold one on me... and then post those pics!

Cheers, Brian
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endwrench  



Joined: 07 Dec 2002
Posts: 1629
Location: Victor, Montana

PostPosted: Fri Mar 21, 2008 1:30 pm    Post subject: Reply with quote

This thread is useless without pics.
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11378
Location: PacNW

PostPosted: Fri Mar 21, 2008 1:49 pm    Post subject: Reply with quote

Indeed a bastard you are.
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Toofah King Bad

  • Red (1987 924S) - Pro44/Spec944
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jgleano  



Joined: 06 Mar 2008
Posts: 18
Location: San Diego, CA

PostPosted: Fri Mar 21, 2008 2:21 pm    Post subject: Reply with quote

ahahahha. I know what you mean... thats the typical "rennlist" reply about no pics.
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Jevan Leano

1989 Guard's Red 944 n/a full turbo body conversion, 931 hood, D90's,

198O (going to be Orange Pearl) 931. MODDED
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morghen  



Joined: 21 Jan 2005
Posts: 8166
Location: Romania

PostPosted: Fri Mar 21, 2008 6:14 pm    Post subject: Reply with quote

cant wait to see some performance figures....could you do some 0-60 tests...maby a 1/4 mile ?
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Ruby-sh 924
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jgleano  



Joined: 06 Mar 2008
Posts: 18
Location: San Diego, CA

PostPosted: Fri Mar 21, 2008 10:12 pm    Post subject: Reply with quote

how many hp gains should you expect when you intercool these cars??? I have no clue....i also need to get mine dynoed.
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Jevan Leano

1989 Guard's Red 944 n/a full turbo body conversion, 931 hood, D90's,

198O (going to be Orange Pearl) 931. MODDED
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11378
Location: PacNW

PostPosted: Sat Mar 22, 2008 3:42 pm    Post subject: Reply with quote

The first step was to relocate the battery. This was professionally done, and wow. 1 ga wire was used from the right rear to the starter (wrapped in fire sleeve and running beneath the torque tube and above the exhaust), and a 12v hot terminal was installed below the overflow tank.

Where did it go?



There it is! Optimal!



Juice, anyone?


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Toofah King Bad

  • Red (1987 924S) - Pro44/Spec944


Last edited by Rasta Monsta on Mon Mar 24, 2008 11:40 am; edited 1 time in total
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11378
Location: PacNW

PostPosted: Sat Mar 22, 2008 3:47 pm    Post subject: Reply with quote

OK, next you gotta assemble the ingredients.

Heat exchanger:



Engine Compartment:



Big box o' shit:



Booze Coffee:



Cool backup car to run to the store:


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Toofah King Bad

  • Red (1987 924S) - Pro44/Spec944


Last edited by Rasta Monsta on Sat Mar 22, 2008 4:04 pm; edited 1 time in total
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11378
Location: PacNW

PostPosted: Sat Mar 22, 2008 3:57 pm    Post subject: Reply with quote

Now install the heat exchanger:



Header panel reinstalled, fastening lip painted.



Here's the heat exchanger through the grilles:



And from the engine compartment:



And from below:



Nice!
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Toofah King Bad

  • Red (1987 924S) - Pro44/Spec944


Last edited by Rasta Monsta on Thu Aug 14, 2008 4:01 am; edited 1 time in total
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11378
Location: PacNW

PostPosted: Sat Mar 22, 2008 4:02 pm    Post subject: Reply with quote

The system needs a pump, which is a bit tricky to install where I want it, mounted up to a wafer-thin box section behind the front bumper.

These inexpensive anchors did the trick:



Slap on some rubber mounts:



And up she goes. Thexthy!



That is clean. . .and mean!
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Toofah King Bad

  • Red (1987 924S) - Pro44/Spec944


Last edited by Rasta Monsta on Sat Mar 22, 2008 4:46 pm; edited 1 time in total
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11378
Location: PacNW

PostPosted: Sat Mar 22, 2008 4:12 pm    Post subject: Reply with quote

For the water plumbing, I utilized my new favorite toy, the crimp clamp. I only used screw-type clamps at those points that absoutely needed to be able to come apart in the future.



Here is where the coolant hoses cross the main firewall:



Note the clear hose. . .my effort to monitor air bubbles, etc., in the coolant system.
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Toofah King Bad

  • Red (1987 924S) - Pro44/Spec944


Last edited by Rasta Monsta on Sat Mar 22, 2008 5:01 pm; edited 1 time in total
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11378
Location: PacNW

PostPosted: Sat Mar 22, 2008 4:16 pm    Post subject: Reply with quote

Next we're gonna swap to a SII manifold, and hack some holes in the car for air and water plumbing.

Mmmm, nice manny!



After obtaining a SII TPS harness from Ryan, the wiring part of the upgrade was like falling off a log. . .the colors for idle and WOT are the same across all models. This upgrade alone made a huge difference in how the car ran. . .neither microswitch on my SI mani was working, largely due to oil soak on the rubber caps. I suspect this is a common condition. . .SI GUYS CHECK YOUR SWITCHES.



You feel lucky, punk?



Ow!


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Toofah King Bad

  • Red (1987 924S) - Pro44/Spec944


Last edited by Rasta Monsta on Sat Mar 22, 2008 5:03 pm; edited 2 times in total
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11378
Location: PacNW

PostPosted: Sat Mar 22, 2008 4:26 pm    Post subject: Reply with quote

Plumbing time!

Here are the layers of tubing as they are added:





Time to add the core.





Yes! YES!

Note the killer boost controller plumbing. Love those crimp clamps!!!


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Toofah King Bad

  • Red (1987 924S) - Pro44/Spec944


Last edited by Rasta Monsta on Sat Mar 22, 2008 4:30 pm; edited 1 time in total
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11378
Location: PacNW

PostPosted: Sat Mar 22, 2008 4:29 pm    Post subject: Reply with quote

Getting close now. I think our pump needs some juice!

Relay this downstairs for me, will you m8?



DONE!


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