924Board.org

[jaspervanweerd]

Hi all,

I have purchased a misc intercooler and I am looking for options to mount it. My goal is to make it look as stock as possible. There are plenty of examples where people chop the charge tube to hook up an intercooler, often front mounts. Or modify it to accommodate a liquid/air cooler... All perfect solutions, but I would like something that is esthetically more pleasing and that looks stock .

Of course one can dish out $1500+ to get a TMIC found on the Carrera models. Even though it is basically bolt on, it still requires one to cut a gaping hole in the bonnet and install the appropriate scoop. I think in all, TMIC, scoop and body work will set you back around $ 2000. Again, a perfect solution (heck Porsche found it good enough for the high performance Carrera models:P) but is does affect the stock look of a 931.

I want something that is equally bolt-on with minimal metal work and when popping the bonnet, everything should look like it was before.

In my opinion that leaves only one place for modification, the lower pressure duct:





What if this same section of metal was replaced by a custom pressure duct that, instead of letting air pass through to the charge tube directly, directs it through a front mount intercooler first.

Well I spend a bit more time on this brain fart and made a 3D model of how such a thing would look like. Bear in mind this was made based on looking at pictures of the original duct and late at night . The real one would require a bit more fine tuning of course.






But I hope this give an idea. piping and such can be routed under the fuel dizzy keeping them out of sight. And fed to the front mount under the head lamp (minor metal work). Even though the cold and hot side are connected by a piece of metal to maintain integrity, heat increase I would expect to minimal..

Of course, I can hear you think... All nice and dandy but how are you planning to fabricate this, under the premise it would all work... (FYI, I don't have any metal work experience or own a welder etc...)

Well, due to the powers of 3D printing you can actually print this in stainless steel. A spin-off company from Phillips actually does this in Eindhoven the Netherlands:


http://www.shapeways.com/materials/steel

Material properties, stainless steel with bronze. Looks like it would suffice for this application...

http://www.shapeways.com/rrstatic/material_docs/mds-stainless.pdf

Well I am looking forward to start a nice discussion about this. In the meantime I will be fine tuning the model and making it more accurate.

Hopefully this will result in an affordable and relatively easy way to install an intercooler on our beloved 931s

Cheers,

Jasper[/url]

[Rasta Monsta]

Fascinating idea. Looking forward to seeing what you come up with.
_________________
Toofah King Bad

• WeiBe (1987 924S 2.5t) - 931 S3

[morghen]

That looks like a nice idea !
What inner diameter do those pipes have?
I'll take a look under the hood to inspect feasibility.
_________________
Supercharger and EFI kits
https://www.the924.com

[Carrera RSR]

Your two limiting factors is space and keeping the flow as short as possible with limited bends that restrict flow. That's before you have to start moving existing components and cutting things. Good luck.

I used the Carrera GTS with a little 944 turbo as inspiration for my install.
_________________
1980 931 - forged pistons, Piper cam, K27/26 3257 6.10 hybrid turbo, 951 FMIC, custom intake, Mittelmotor dizzy & cam pulley, H&S exhaust, GAZ Gold, Fuch'ed, Quaife
Now www.924board.org/viewtopic.php?t=34690
Then www.924board.org/viewtopic.php?t=31252

[kcoyle]

Great idea, but from what I see there is no room for anything like that. Between the fuel distributor, frame rail, and body itself it's mad tight.
Maybe your piping with a fuel distributor relocation?

I've stared at that part of the car drinking beer and sometimes coffee, and neither have helped with a good IC idea. probably any good ideas actually.

Some crappy pics for reference.







_________________
1982 931- Stock with MBC at 8psi

Relax, all right? My old man is a television repairman, he's got this ultimate set of tools. I can fix it.

[Rasta Monsta]

I think there was a Holbert IC setup in that area. Obviously no squirt bottle.
_________________
Toofah King Bad

• WeiBe (1987 924S 2.5t) - 931 S3

[Cedric]

Neat solution, I thought about fabricating a similar, but I cant see how there would be enough space. one tube could go under the CIS, but I cant see both going past there. But try hard, I hope it works...

When you are done with your design send me an .stl and I will print it in 3d (plastic) and do a test assembly
_________________
1980 924 Turbo
www.instagram.com/garagecedric/

[924RACR]

My current thoughts on FMIC... I aim to add the 951 IC, starting with stock turbo and CIS.

Ultimately I intend to rework the intake to put the throttle body up front just like the 951, for cleaner airflow path... but for now, I think what I'll do is eliminate the charge tube and pressure duct entirely.

I plan to use a silicone connector hose with a 90 deg aluminum bend to shoot forward to the IC, under the CIS fuel distributor... then back with a straight pipe and bend (approx 135 deg) back into the stock throttle body (with another silicone connector hose section).

This should be relatively easy to make, other than a couple of aluminum welds (but I can do those easily), and also pretty easy to mod out to relocate the throttle body and eliminate the CIS when I'm ready...

No, no pics, sorry...
_________________
Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

[kcoyle]

[Carrera RSR]

[morghen]

emoore924's car could have pop-ul lights.
mine does and i use thicker pipes




_________________
Supercharger and EFI kits
https://www.the924.com

[kcoyle]

Morghens car for headlight reference. Do you have more room for the IC due to the different front end?


_________________
1982 931- Stock with MBC at 8psi

Relax, all right? My old man is a television repairman, he's got this ultimate set of tools. I can fix it.

[morghen]

I had a custom front bumper and it had much more room..but its gone now.

I have the 951 front end(glass fiber) and the 951 bumper offers alot less space so right now the intercooler is mounted 1inch from the radiator and it sits vertically. However the routing inside the engine bay is identical.
_________________
Supercharger and EFI kits
https://www.the924.com

[emoore924]

No Pop up lights on that car.

[nwns]

One of dan's top mount chargecoolers is the only bolt on, no cutting, easy remove way. Everything else is a lot of work.
_________________
Pete