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THE ULTIMATE 951 INTERCOOLER INSTALL
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Scorpio  



Joined: 05 Jul 2007
Posts: 1957
Location: Brisbane, Australia

PostPosted: Thu Oct 02, 2008 8:12 am    Post subject: THE ULTIMATE 951 INTERCOOLER INSTALL Reply with quote

Finally i can give something back to the 924 community !

At first i didnt think the 951 intercooler would fit but as it turns out it does...ENJOY

1- REMOVE HEADER PANEL - USE SPOT WELD DRILL BIT TO REMOVE SPOT WELDS

Header Panel

Removing spot welds

Underside of header panel spot welds

Removed header panel









2- YOU WILL NEED TO CUT A LARGE SECTION OF SHEET METAL- I USED A GRINDER WITH A CUTTING DISK AND A JIGSAW


Section under panel




Section to be cut-- cut flat section A then vertical section in blue B...use your own intercooler as a guide..you want a snug fit to ensure air doesnt escape around the sides..youll see later on


Showing roughly cut section...blue section still needs to be cut down...red arrow indicates where about to stop cut..



3- REINFORCE THIN SLITHER THAT WAS LEFT USING ALUMINIUM OR STEEL SQUARE LENGTHS
Reinforcing brace made from steel L section self tapering screwed onto aluminium square section--- I used aluminium cause it was easy to work with..those that can weld can use steel...
Reinforcing section pic


Section being placed into brace

section self tapering screwed into brace...note that welders should weld...as it turns out the reinforcment when self tapering screwed in was more that sufficient

Por 15 to prevent rust then fix reinforcing in

Run a line of self tapering screws along through sheet to aluminium section(or weld if you can be bothered)..pic shows fully cut section


4- TRIAL FIT INTERCOOLER


This step is actually an ongoing step but for purposes of illustrating the fit

Pic b4 cutting was finished

Rough sitting position from engine side (will need some adjusting)



5- CREATE 4 ALUMINIUM BRACKETS- Youll need to create aluminium brackets to mount the 4 corner attachments on the intercooler to the car..i used 3 mm bar section bent in a vice..getting the right angle is trial and error.




The two lower brackets are attached to the main chassis cross member with 4 self tapering screws (and por 15 glued) wheres the top 2 each have 2 bolts bolting them to the headlight support section...The install actually turns out extremely rigid and a hell of a lot stronger then the radiator supports
This is how the intercooler and brackets sits in the car


6-MAKE AN AIR DAM TO CONTROL AIRFLOW INTO THE INTERCOOLER Set intercooler in position then use cardboard to roughly shape an air dam so that incoming air doesnt divert around instead of through the intercooler
Cardboard template fitting

Cardboard template


Use the cardboard template to shape the same dam out of aluminium sheet..i used 2 mm sheet although 1.2 or 1.4 mm sheet would be easier to work with...
The shape was cut in a scroll saw and angles bent in a vice..again trial and error then more bending.

View of rough aluminium dam


Top view of aluminium dam- note that dam will be bolted through intercooler lip to prevent reverberation



NOTE THAT THE ORIENTATION I CHOSE FOR THE INTERCOOLER WAS ONE WHEREBY THE LIP AT THE FRONT OF THE INTERCOOLER WAS AT THE TOP..YOU CAN HAVE IT THE OTHER WAY IF YOU WANT,THIS WAY WAS EASIER FOR MAKING MOUNTING BRACKETS AND FASTENING THE AIR DAM

7- TRIAL TEST FIT AGAIN WITH HEADER PANEL, DE BURR AREA, PAINT AND FIT USING RUBBER INSULATION GROMMETS

Rubber insulators on mounting holes to prevent heat trasfer and corrosion into body


Rubber insulators


Header panel test fit




NOTE- BONNET CLEARANCE COULD ALSO BE AN ISSUE ASWELL AS HEADLIGHT MOTOR TORSION ROD...BUT ILL CROSS THAT BRIDGE LATER..SO FAR IT LOOKS AS THOUGH EVERYTHING WILL FIT OR COME CLOSE TO IT


THE FINAL PRODUCT








_________________
1979 NA
MS1..EFI..
GARRETT T25 TURBO
BILSTEIN SHOCKS
GT BASED CUSTOM BODYKIT

Brisbane , Australia
Think mean think fast
all youll see is
my Porsches Arse!!!


Last edited by Scorpio on Thu Oct 02, 2008 12:57 pm; edited 3 times in total
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ideola  



Joined: 01 Oct 2004
Posts: 15548
Location: Spring Lake MI

PostPosted: Thu Oct 02, 2008 9:30 am    Post subject: Reply with quote

Scorpio, nice pix & writeup! Congrats on the progress!
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Scorpio  



Joined: 05 Jul 2007
Posts: 1957
Location: Brisbane, Australia

PostPosted: Thu Oct 02, 2008 4:35 pm    Post subject: Reply with quote

For those interested , the following pics shows s rough setup of the air intake i chose. Those who have access to a 931 panel use that..

I found this nice little intake section at the wreckers, i think its off a ford although the wrecker dude thinks its from a skyline..turns out to be a close to fit and willensure alot of air gets in for cooling , with a bit of cutting and moulding of course.

I need to add some styling to it though somehow..hmmm




_________________
1979 NA
MS1..EFI..
GARRETT T25 TURBO
BILSTEIN SHOCKS
GT BASED CUSTOM BODYKIT

Brisbane , Australia
Think mean think fast
all youll see is
my Porsches Arse!!!
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elitejaso  



Joined: 24 Jul 2007
Posts: 138
Location: Melbourne

PostPosted: Mon Oct 06, 2008 10:26 am    Post subject: Reply with quote

Nice writeup scorpio, very cool
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Adismo  



Joined: 05 Oct 2008
Posts: 80
Location: Guatemala

PostPosted: Tue Oct 07, 2008 3:59 pm    Post subject: Reply with quote

And how works the light bars??
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Scorpio  



Joined: 05 Jul 2007
Posts: 1957
Location: Brisbane, Australia

PostPosted: Tue Oct 07, 2008 4:11 pm    Post subject: Reply with quote

Quote:
And how works the light bars??

havent test fitted them...but worst case scenario they dont fit...i go GT lights
_________________
1979 NA
MS1..EFI..
GARRETT T25 TURBO
BILSTEIN SHOCKS
GT BASED CUSTOM BODYKIT

Brisbane , Australia
Think mean think fast
all youll see is
my Porsches Arse!!!
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leadfoot  



Joined: 11 Dec 2002
Posts: 2222
Location: gOLD cOAST Australia

PostPosted: Wed Nov 05, 2008 4:00 pm    Post subject: Reply with quote

Nice work...
Think Maybe about getting a Fiberglass header panel, I'm sure Dan might be able to hook you up with a 931 panel otherwise...
Stu.
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1981 ROW 924 Turbo -
carbon fiber GT mish mash
LS1 conversion in progress...
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Joes924Racer  



Joined: 03 Nov 2002
Posts: 11964
Location: Oregon, Denver Colorado native!

PostPosted: Thu Jan 22, 2009 6:51 pm    Post subject: Reply with quote

Ya scorpio looks good .. i want more pics though if you have any..
whats the finish date this summer.
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1979 porsche 924 Na
1980 porsche Turbo 931GT Replica
Have u ever driven a turbo.
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gegge  



Joined: 27 Jul 2007
Posts: 1124
Location: Sweden

PostPosted: Fri Jan 30, 2009 10:14 pm    Post subject: Reply with quote

You have made me change my mind, leaving the complicated water-air ic setup in favour of 951 ic.

Two questions:

* Is it possible to fit the 951 intercooler without removing the header panel? For example cutting and removing the bonnet lock and brace or by accessing the area from underside in front of the radiator?

* Since an intercooler have hot air entering and cold air leaving I would say that the flow is different depending on direction. The major restriction is the "first" elbow as I understand it, and cold air takes less space and therefore would the intercooler be more effective backwards/upsidedown?
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Carl Fredrik Torkildsen

924 turbo -81 Carrera GT RESTOMOD
924 turbo -80 Dolomite De Luxe
924 -85 DP kit, BBS RS, M030 and tuned engine
924s -86 Black on black turbo with Fuchs
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11723
Location: PacNW

PostPosted: Sat Jan 31, 2009 4:06 am    Post subject: Reply with quote

Header panel comes off in 30 minutes (I've now done three of them), and can be reinstalled quite cleanly (click the pic).



There is really no reason not to proceed this way, IMO.
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  • WeiBe (1987 924S 2.5t) - 931 S3
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PORSCHEV  



Joined: 02 Nov 2002
Posts: 1901
Location: Cedar Lake Nova Scotia, Canada

PostPosted: Sat Jan 31, 2009 7:02 am    Post subject: Reply with quote

I am sorry..but that looks like a total hack and screw a bunch of crap together. Good effort if your 13 years old.

Good job on spraying it all shinny black to hide how Crappy it looks!!

It's NOT a good how to ..IT is however a great how NOT to.
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1976 924
5 lug conversion, 17'C2 wheels,custom body work,327 vette engine.

1978-#53 "D" track racer.
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11723
Location: PacNW

PostPosted: Sat Jan 31, 2009 7:04 am    Post subject: Reply with quote

Holy moly, must be happy hour already out east. . .you sound like our old pal Neil!
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  • WeiBe (1987 924S 2.5t) - 931 S3
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PORSCHEV  



Joined: 02 Nov 2002
Posts: 1901
Location: Cedar Lake Nova Scotia, Canada

PostPosted: Sat Jan 31, 2009 7:11 am    Post subject: Reply with quote

Well come on ..... he hacks the hole to big for the intercooler. Drops it in place then screws and GLUES the support back in place with a make shift brace. Makes some flimsly aluminum brackets and self tappers them in place. It looks like crap. Now he has 15 spot welds drilled out on the header panel. I guess he'll just screw those down and slide some seam sealer over those too.

To hell with Neil...he couldn't even change his own tire!!!
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1976 924
5 lug conversion, 17'C2 wheels,custom body work,327 vette engine.

1978-#53 "D" track racer.
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PORSCHEV  



Joined: 02 Nov 2002
Posts: 1901
Location: Cedar Lake Nova Scotia, Canada

PostPosted: Sat Jan 31, 2009 7:15 am    Post subject: Reply with quote

It might be that I just washed the V8 beast and I am working on installing my own version of the GT headlighs. My car is Pristine and all fab work is well done and well thought out. Not just hack and tack ..glue and screw.

No one will see this and that.

I painted my under carriage and suspension so I do care what other people see.
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1976 924
5 lug conversion, 17'C2 wheels,custom body work,327 vette engine.

1978-#53 "D" track racer.
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11723
Location: PacNW

PostPosted: Sat Jan 31, 2009 7:54 am    Post subject: Reply with quote

PORSCHEV wrote:
Now he has 15 spot welds drilled out on the header panel. I guess he'll just screw those down and slide some seam sealer over those too.


That sounds oddly familiar. . .oh yeah, that is what I did.


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  • WeiBe (1987 924S 2.5t) - 931 S3
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