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intercooler setup *UPDATE*
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morghen  



Joined: 21 Jan 2005
Posts: 8127
Location: Romania

PostPosted: Sun May 18, 2008 6:24 am    Post subject: intercooler setup *UPDATE* Reply with quote

So...its my turn to cool it down a bit.

i've designed an intercooler and produced the drawing for a company who actualy welded it together. If my calculations are correct this IC should be good for 250 BHP so the S2 931 engine is safe with it.

today i've done the first chapter:

-design and route guides for the real piping.
-search for possible space problems and find solutions
-start on the actual piping

my plan is to use as much stock parts as possible...so i'm going to cut the charge tube and the smaller part of it and fit rubber tubes.

intercooler is mounted in front and its tilted for space reasons.
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Ruby-sh 924


Last edited by morghen on Sun May 25, 2008 9:27 am; edited 2 times in total
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11378
Location: PacNW

PostPosted: Sun May 18, 2008 7:14 am    Post subject: Reply with quote

Looking for comments? I would be concerned about the length of your intake tract, and air flow through your radiator.
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Toofah King Bad

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



Joined: 21 Jan 2005
Posts: 8127
Location: Romania

PostPosted: Sun May 18, 2008 7:47 am    Post subject: Reply with quote

hey....yea looking for comments.

hmm...seen intercoolers put right next to the radiators and they were fine...any other comments on this point?

Lenght...my goal was to minimise the lenght...and i think its short for a FMIC...maby the long pipes create some sort of image distortion but the whole thing is not that long and i think that i'm going to move the intercooler more to the left so i can have an even shorter tract...any other comments on this ?
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Ruby-sh 924
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Paul  



Joined: 02 Nov 2002
Posts: 9414
Location: Southeast Wisconsin

PostPosted: Sun May 18, 2008 7:58 am    Post subject: Reply with quote

The hoses must not touch the inner fender since a 931 motor moves left and right on it's mounts (like most rear drive cars).

What do you plan to cover that IC with?
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Silver 98 986 3.6l 320 HP "Frank N Stein"
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CÚdric  



Joined: 27 Aug 2004
Posts: 1930
Location: Sweden

PostPosted: Sun May 18, 2008 8:05 am    Post subject: Reply with quote

I dont think the lenght will be a problem. But what front bumper do you have?
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morghen  



Joined: 21 Jan 2005
Posts: 8127
Location: Romania

PostPosted: Sun May 18, 2008 8:43 am    Post subject: Reply with quote

I've seen the hooses problem....i've sticked feltpads to minimise friction for now but i'm looking to reduce contact to 0. thanks.

CÚdric wrote:
I dont think the lenght will be a problem. But what front bumper do you have?


a big and fat one


Rasta might be right about the radiator getting less cold air...i might need a performance radiator...

the silver grid on the front bumper will come off and i will duct the air for the radiator and intercooler separatly as i did for the brakes.

one more point i'd like some opinions about is venting the exhaust manifold area. porsche have done it on the 931 with that hood scoop. i'm using a NA hood and there is no way i'm cutting my hood or mounting anything on it. so i want to duct some air from the front to the exhaust manifold area...ofcourse the air stream would not directly hit the manifold...
any toughts?
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Ruby-sh 924
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endwrench  



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

PostPosted: Sun May 18, 2008 8:55 am    Post subject: Reply with quote

morghen wrote:


hmm...seen intercoolers put right next to the radiators and they were fine...any other comments on this point?


Been there, done that. It doesn't work well. You need a little space between the IC and the rad because the IC tubes are so wide they only flow air thru half the frontal area. Your IC should flow plenty of air to cool the radiator but to make it efficient you need to duct\seal it to the radiator so NO air can flow around the rad after going thru the IC. This will make both the IC and the radiator work better.

Todd
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'79 924NA. Rebuilt 9.5:1, MSDS header, Mega Squirt Injection, MJLJ-EDIS Ignition, 1.6L Whipple Charger and Intercooler, 10lbs Boost, 944 Trans, Custom HD Clutch.
"simsport" said....superchargers are better than turbos its official!....
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morghen  



Joined: 21 Jan 2005
Posts: 8127
Location: Romania

PostPosted: Sat May 24, 2008 11:39 pm    Post subject: Reply with quote

update: had some spare time to work on the IC setup. Ofcourse nothing is final...i'm going to get a professional shop to make the whole thing out of INOX after its ready. But this looks good to me.
In the first picture i'm using a very long rubber piece(left)..i will replace that with a solid pipe in the afternoon.



Cant wait to start her up and go for a spin to see the differences.
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-nick  



Joined: 16 Nov 2002
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Location: Cambridge, MA

PostPosted: Mon May 26, 2008 1:33 am    Post subject: Reply with quote

Looks like a solid idea. Why not move it over to the passenger side and make your duct work shorter though?
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1991 964 C4 Cabriolet
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morghen  



Joined: 21 Jan 2005
Posts: 8127
Location: Romania

PostPosted: Fri May 30, 2008 9:28 am    Post subject: Reply with quote

so....got it welded...its a two piece thing...one for the input of the IC and one for the output.
it still needs some tweaking...but mainly its there and it works.

the first thing i've noticed is that the engine sounds different....in a good way.
second thing...i was expecting the boost to come early and stuff like this...but no...boost is there where it should be. 3.5K RPM...max torque is at 4000 and keeps pulling to 6000. i havent really tested it because i'm using rubber for the aluminium to inox parts and i did not want to have to fix the car on the way home.
The turbo does not sing so loud anymore...and all the sounds are deeper..lower....sounds like a bigger engine.

some bad things....HOT start problem seems to have gone worse.....but this can be related to piping...and i miss the turbo singing

i'll post pictures as soon as i make them.
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Rasta Monsta  



Joined: 12 Jul 2006
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PostPosted: Fri May 30, 2008 10:03 am    Post subject: Reply with quote

3.5 sounds low to me, but that could be my boost controller. Shaggy's boost is at 50% at under 2.5, and 100% under 3k.
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Toofah King Bad

  • Red (1987 924S) - Pro44/Spec944
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moone924  



Joined: 05 Feb 2003
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Location: Douglas Wyoming

PostPosted: Fri May 30, 2008 6:49 pm    Post subject: Reply with quote

open up your exhaust and you can hear the turbo sing from the other end.
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Always shopping for a nice s2 931 to baby.
New philosophy : one car project at a time.
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ideola  



Joined: 01 Oct 2004
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Location: Woodstock IL

PostPosted: Fri May 30, 2008 10:23 pm    Post subject: Reply with quote

Rasta Monsta wrote:
3.5 sounds low to me, but that could be my boost controller. Shaggy's boost is at 50% at under 2.5, and 100% under 3k.

Could it be the difference between SI and SII turbo unit???
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morghen  



Joined: 21 Jan 2005
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Location: Romania

PostPosted: Fri May 30, 2008 10:45 pm    Post subject: Reply with quote

well mine is an S2 so i should have less lag...could be that i have some leak in the intake system as i am not using silicone joints but rubber joints and the piping needs a small revision to sit flush with the body and engine...i had no time to check for leaks...i started the car as soon as i had everything bolted. I will have the whole piping retuched and leak tested next week. cant wait to take some pictures and give it the beans

as a straight result...before i could not even get close to the intake manifold after a few "laps"...now its cold as ice !
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ideola  



Joined: 01 Oct 2004
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PostPosted: Fri May 30, 2008 10:57 pm    Post subject: Reply with quote

Where the boost comes on in the RPM range has nothing to do with lag...but 3500 RPM does seem a bit late for an SII. I thought they were designed to spool quicker. I dunno, I have SI...no boost gauge yet, but it starts to kick in at 2500...
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