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BOLT ON INTERCOOLER?
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So What has the most appeal? - That is what should I try to put together for the Masses?
AIR TO WATER - TOP MOUNT
0%
 0%  [ 0 ]
AIR TO WATER - NOSE MOUNT
10%
 10%  [ 3 ]
AIR TO AIR - TOP MOUNT CGT/937 STYLE
36%
 36%  [ 11 ]
AIR TO AIR FRONT MOUNT
16%
 16%  [ 5 ]
AIR TO AIR NOSE MOUNT - 951 STYLE
10%
 10%  [ 3 ]
AIR TO WATER BARREL STYLE
10%
 10%  [ 3 ]
WHAT? OH GREAT ANOTHER POST FROM THE MAD HATTER
10%
 10%  [ 3 ]
WTF - WHO CARES
3%
 3%  [ 1 ]
SOME ONE SEDATE THIS GUY ALREADY
3%
 3%  [ 1 ]
Total Votes : 30

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ESC944  



Joined: 21 May 2004
Posts: 747
Location: FL

PostPosted: Mon Mar 13, 2006 2:19 am    Post subject: BOLT ON INTERCOOLER? Reply with quote

Alrighty - over under my latest toy thread the discussion of a bolt on 937 style intercooler came up as well as general intercooler.

So the basic commentary was:
Khal wrote:
Did you make that? I mean, yourself... with your own two hands?

I read your description but I'm still not sure if I understand exactly what it is..?

It's a throttle-body spacer with twin injectors. For more fuel or NOS. Have I got that right?

It looks awesome. If you can make that stuff, why do I not see a bolt-on intercooler kit yet?!!! Please, I'm begging you, make something that us dummies can actually use!


AND:
flosho wrote:
ESC, I would say just something that is simple and works and is a bolt on deal.. At least to me it doesn't really matter if it is a replica or not, and keeping my stock hood, well stock, is much more pleasing to me.

Or do a front mount intercooler with the pipes to hook it all up, no need for a water sprayer or anything like that.. Just a nice clean FM.


So then I am thinking I have enough intercoolers and intercooler cores and my 931 available - So what is it going to be chaps?

I see these considerations:

AIR TO WATER - TOP MOUNT
AIR TO WATER - NOSE MOUNT - 951 STYLE ONLY WATER INSTEAD OF AIR
AIR TO AIR - TOP MOUNT CGT/937 STYLE - REQUIRES A HOLE IN THE HOOD
AIR TO AIR FRONT MOUNT
AIR TO AIR NOSE MOUNT - 951 STYLE
AIR TO WATER BARREL STYLE


Now I like air to water - but it adds complexity
    lots of parts and plumbing
    Tank
    Pump
    Small Radiator
    No hole in hood for top mount


Top mount A2A - limited in size

    Hole in the hood
    Seals
    Hood Scoop
    May not be for everyone


Nose mount requires almost as much plumbing as front mount

    Also limited on size
    Of course requires the nose be removed so you can install IC
    Can open area up for larger unit
    Removing Nose and/or Mods for larger IC lot of work for the end user
    I can see a kit with hardware to facilitate reinstall of nose or even fiberglass or carbon fiber replacement


Front Mount - requires longest runs of intake pipes

    Can cause heat issues with radiator
    Would require 2 fans on radiator - 6 fin - 951 style or aftermarket
    Unit would need to be flush mounted to radiator or AC core.


Barrel Style - can be installed in line with pipes - but still A2W

    Requires same stuff as other Air to water
    Smaller profile
    Easy to install in line - like installing any hard pipe
    Can use more than one - but can be expensive


I will post pictures after I get back from church
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Raceboy  



Joined: 01 Mar 2004
Posts: 2327
Location: Estonia, Europe

PostPosted: Mon Mar 13, 2006 2:34 am    Post subject: Reply with quote

GTR style: front mount, direction: air enters IC from underside and IC outlet straight to the log-style inlet manifold. Very short plumbing.
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'84 928 S, sold
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ESC944  



Joined: 21 May 2004
Posts: 747
Location: FL

PostPosted: Mon Mar 13, 2006 2:42 am    Post subject: Reply with quote

YES CAN DO THAT AS WELL
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sequential  



Joined: 18 Nov 2005
Posts: 500
Location: BANNED

PostPosted: Mon Mar 13, 2006 6:42 am    Post subject: Reply with quote

the most feasible is the CGT style as it will bolt right in and require the least amount of modification to work . it will also be the least expensive
because of the core size ( a plus here ) at .8 bar the intercooler will be effective possible to 1 bar and with a new style bar and plate cooler it will work for most here .
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hausbrauen  



Joined: 26 Sep 2005
Posts: 87
Location: 313 USA

PostPosted: Mon Mar 13, 2006 7:03 am    Post subject: Reply with quote

How about a top mount air to water that is designed to replicate the CGT but does not require a hood scoop?
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wannaBgroupB  



Joined: 09 Mar 2006
Posts: 13
Location: Augusta, GA

PostPosted: Mon Mar 13, 2006 9:57 am    Post subject: Reply with quote

Top-mount air to air....big honkin' hood scoops are sexy.
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Khal  



Joined: 26 Sep 2003
Posts: 4872
Location: Sunny and lovely interior BC, Canada

PostPosted: Mon Mar 13, 2006 11:15 am    Post subject: Reply with quote

sequential wrote:
the most feasible is the CGT style as it will bolt right in and require the least amount of modification to work . it will also be the least expensive
because of the core size ( a plus here ) at .8 bar the intercooler will be effective possible to 1 bar and with a new style bar and plate cooler it will work for most here .


Agreed.

As with most things, there's probably a damn good reason why Porsche put the intercooler on top... and my guess is it's simply because it wouldn't fit anywhere else. I don't see any reason to mess with their idea.

And try to keep in mind that not all of us are looking to build 500hp monsters A small, neat, air-to-air top-mount that gives some improvement would be quite nice, thanks. I'd prefer not to have the hood scoop but I'll do it if it's necessary (besides, I really like the look of SoyRacer's car )
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flosho  



Joined: 01 Jul 2004
Posts: 3160
Location: Eau Claire, Wisconsin

PostPosted: Mon Mar 13, 2006 12:56 pm    Post subject: Reply with quote

I would vote but I really can't decide on which one I would most want.

Just going over how I feel about everything here.

Topmount:
Does it mach up right by the NACA duct or will we have to purchase a 924/944 hood and cut that up? Or exactly how would the scoop work, I'm not opposed to using the top mount air to air, as it would be real reasonable.

However, what kind of heat soak issues would we suffer in daily driving traffic. It would be sitting right over the exhaust manifold. This would keep plumbing to a minimum and still be efficient, I mean STi's use a top mount and are makin' 300hp so that should be sufficient for most of us..

air/water
This setup is kinda what I'm thinking is like Kenodog's air/water set up. The only draw back is that this would be much more money, however we can keep our stock hoods and stock intake manifolds.

Everyone says this setup is more of a drag racing style set up, not really to be used as a daily driver. I don't daily drive my car but I drive it whenever I can and when its nice out so I wouldn't want this setup if its not suitable for normal driving.

front mount:
Longer pipes, higher engine temps because the front of our cars aren't exactly good for allowing a front mount, this would probably be more cost efficient than air/water but would induce some lag into our powerband..

Then again if we use a log style manifold it isn't going to be any less expensive then an air/water setup

Nose style front mount:
I think the air flow isn't going to be great enough and there isn't enough room to put a good sized intercooler in the nose.. (then again I haven't looked at my car in 4 months... so there could be more room in there than I remember...)

I think an air/water top mount is unreasable becuase it would be less of a head ache to do an CGT top mount instead... same with an air/water nose mount, running something similar to kenodog's setup would allow for a greater core and better cooling..

I guess my vote goes for front mount or carrera gt top mount.. otherwise an air/water in the battery tray.. one of those three..

Another thing that you could think about is just a simple alcohal/water injection system w/o an intercooler... or even on a top mount or front mount with water injection..

Oh..is church over now?
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CBass  



Joined: 03 Nov 2002
Posts: 2807
Location: Vancouver, Canada

PostPosted: Mon Mar 13, 2006 1:21 pm    Post subject: Reply with quote

I think we have two winners.

Make a Carrera GT style intercooler that most people can bolt on their car without having to take off their badge panel and modify the bracing(951 style). For engines running at lower boost levels, .5-1.0 bar.

Make a large front mount with it's own intake manifold. The most efficient way, for engines running 1.0+ bar.
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sequential  



Joined: 18 Nov 2005
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PostPosted: Mon Mar 13, 2006 4:20 pm    Post subject: Reply with quote

Hey narrow down the poll options , the masses will always buy black , until you give them a choice.
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928 gts prototype
baby blue engine block
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cold star issues while on stands
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ESC944  



Joined: 21 May 2004
Posts: 747
Location: FL

PostPosted: Mon Mar 13, 2006 4:29 pm    Post subject: Reply with quote

Well I dont think you can reduce the poll options.

Alright so I am back - long day.

Church - then ran into some of the Ford guys, who are part of the local club and go to my church - they are all worked up about my v6 kit and the kit I am carrying that converts the 99-04 stang into a more 06 GT looking ride. That turned into a tune session and BBQ - we grilled some burgers and dogs, kids played on the slip and slide and we upgrade the XR7 - new intercooler - new injectors, MAFTuner kit, Chip, tweaking - was making 600HP last dyno - 351 twin turbo. Any who - long day, good times.

Sorry About the long delay.

So lets do some pics shall we?
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ESC944  



Joined: 21 May 2004
Posts: 747
Location: FL

PostPosted: Mon Mar 13, 2006 5:01 pm    Post subject: Reply with quote

Well one way to go about it for the DIY - convert something - like air to water:







Front Mount -
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ESC944  



Joined: 21 May 2004
Posts: 747
Location: FL

PostPosted: Mon Mar 13, 2006 6:12 pm    Post subject: Reply with quote



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ESC944  



Joined: 21 May 2004
Posts: 747
Location: FL

PostPosted: Mon Mar 13, 2006 6:27 pm    Post subject: Reply with quote

TOP MOUNT
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81turbo  



Joined: 03 Nov 2002
Posts: 1065
Location: Oakland, CA

PostPosted: Tue Mar 14, 2006 4:54 am    Post subject: Reply with quote

That Ford top-mount will not clear the hood on the 931. I have tried to mock up a fitting and it is about and inch or so too tall. It is a shame that is a very nice core!
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