Show full size 924Board.org
Discussion Forum of 924.org
 
 FAQFAQ   SearchSearch   MemberlistMemberlist   UsergroupsUsergroups   RegisterRegister 
 ProfileProfile   Log in to check your private messagesLog in to check your private messages   Log inLog in 
 Technical FAQ924 FAQ (Technical)   Technical924 Technical Section   Jump to 924.org924.org   Jump to PCA 924 Registry924 Registry

Ideola Liquid to Air Intercooler Install
Goto page 1, 2, 3  Next
 
Post new topic   Reply to topic    924Board.org Forum Index -> Performance Upgrades
View previous topic :: View next topic  
Author Message
Mike9311  



Joined: 14 Dec 2004
Posts: 677
Location: Chicago-ish

PostPosted: Fri Sep 01, 2017 4:32 am    Post subject: Ideola Liquid to Air Intercooler Install Reply with quote

So I am back at it again...

Trying to bang this out before the Sept gathering.

At least 7 re-designs and 7 3D printed plastic test pieces before being happy "enough" to go to machining. Not even sure if this will work out. Would have/should have 3d printed in Alum but here goes nothing.







Keep in mind this is only partially roughed out

[/img]
_________________
1980 931 ...off with the cobwebs
1982 931 Entwicklungsfahrzeug
1979 924 NA M471/M481 / ohne M650 Herausnehmbares Dach
0.5 1982 931 smashed parts car
1982 931 parts car?
1980 924 NA (R&D lightweight)
1982 931 WB wana-be GTR race car


Last edited by Mike9311 on Tue Sep 05, 2017 5:50 am; edited 1 time in total
Back to top
View user's profile Send private message
ideola  



Joined: 01 Oct 2004
Posts: 15509
Location: Woodstock IL

PostPosted: Fri Sep 01, 2017 4:40 am    Post subject: Reply with quote

Oooooooooooooooooooooooooh! Want want want!
_________________
15 981 GTS | 88 924S SE | 82 931 Holbert | 82 931 Rallye | 81 937 | 81 Euro 931 | 81 Weissach | 80 US 928 | 80 US 931 '941' | 80 US 931 | 80 931 GTR | 79 Sebring | 78 D-Prod Replica | 78 w/D-Prod kit | 78 Poli-Form | 78 Limited Edition | 77 Martini
Back to top
View user's profile Send private message
Mike9311  



Joined: 14 Dec 2004
Posts: 677
Location: Chicago-ish

PostPosted: Fri Sep 01, 2017 4:56 am    Post subject: Reply with quote

ideola wrote:
Oooooooooooooooooooooooooh! Want want want!




_________________
1980 931 ...off with the cobwebs
1982 931 Entwicklungsfahrzeug
1979 924 NA M471/M481 / ohne M650 Herausnehmbares Dach
0.5 1982 931 smashed parts car
1982 931 parts car?
1980 924 NA (R&D lightweight)
1982 931 WB wana-be GTR race car
Back to top
View user's profile Send private message
morghen  



Joined: 21 Jan 2005
Posts: 7886
Location: Romania

PostPosted: Fri Sep 01, 2017 5:46 am    Post subject: Reply with quote

Jesus! Mights as well have milled it from a cubic foot
Why didnt you cast that? Would have been easy and cheap.
Or have it from a bent pipe and a milled flange...ic looks welded so..
_________________
red 924 and not red 924
Back to top
View user's profile Send private message Visit poster's website Yahoo Messenger MSN Messenger
CÚdric  



Joined: 27 Aug 2004
Posts: 1751
Location: Sweden

PostPosted: Fri Sep 01, 2017 5:55 am    Post subject: Reply with quote

morghen wrote:
Jesus! Mights as well have milled it from a cubic foot
Why didnt you cast that? Would have been easy and cheap.
Or have it from a bent pipe and a milled flange...ic looks welded so..


Haha, around here we often joke about the Americans fondness of billet everything, whether it's needed is less important

Great work! Seems fun, and i guess you have great machines at your work place. Sometimes i wish i didn't work at such a big place, almost everything fun (like borrowing the cool machines) is forbidden..
_________________
┤80 924 Turbo
Back to top
View user's profile Send private message MSN Messenger
ideola  



Joined: 01 Oct 2004
Posts: 15509
Location: Woodstock IL

PostPosted: Fri Sep 01, 2017 6:12 am    Post subject: Reply with quote

Casting is neither easy nor cheap. Trust me, I've looked. You can't find anyone who will do any alu casting for less than 10,000 pieces. And we've already seen what new cast GTR manifolds go for.
_________________
15 981 GTS | 88 924S SE | 82 931 Holbert | 82 931 Rallye | 81 937 | 81 Euro 931 | 81 Weissach | 80 US 928 | 80 US 931 '941' | 80 US 931 | 80 931 GTR | 79 Sebring | 78 D-Prod Replica | 78 w/D-Prod kit | 78 Poli-Form | 78 Limited Edition | 77 Martini
Back to top
View user's profile Send private message
Kenodog  



Joined: 25 Jun 2003
Posts: 2455
Location: Vancouver,B.C.

PostPosted: Fri Sep 01, 2017 6:26 am    Post subject: Reply with quote

Au contrair. Casting is cheap and easy. As I mentioned before in a different thread I had a quote of $5,000 Cdn. to make a mold for casting new 931 exhaust manifolds. After that you simply pay a small set-up fee for each run and then by the pound for the raw material. Inconel 625 was quoted to me at $2/lb.

Mike's little part is ridiculously simple for a mold. The problem is finding enough people to cough up the dough to split the mold cost. Each unit after that would be peanuts though.
_________________
1979 Euro 931, Olive
1981 931, Sabine
2014 Mazda CX-5 (Kid's limo)
2008 GS500
1996 Dodge Caravan (DJV)
Back to top
View user's profile Send private message Send e-mail MSN Messenger
Mike9311  



Joined: 14 Dec 2004
Posts: 677
Location: Chicago-ish

PostPosted: Fri Sep 01, 2017 6:37 am    Post subject: Reply with quote

The whole idea wasn't mine since I too thought it a tad crazy. I was challenged by my father.

Obviously I am doing it because I have the equipment but by no means did I think it was optimal. Normally this is fun but I am struggling a tad right now on my approach

Two things did push me to at least try though. First I have seen something like this done so I wanted to see if I could and, second, to push the skills a bit. If I can't do this, I certainly cant do anything "head" related. Ultimately that's where I am headed down the road.

Somewhere back in my mind I think often of what CarreraRSR did with making something look like it was supposed to be there all along. I tip my hat to Steve frequently and I hope this turns out that way.

Maybe I should just cast it myself I'll think about it since I did do something like that once long ago...
_________________
1980 931 ...off with the cobwebs
1982 931 Entwicklungsfahrzeug
1979 924 NA M471/M481 / ohne M650 Herausnehmbares Dach
0.5 1982 931 smashed parts car
1982 931 parts car?
1980 924 NA (R&D lightweight)
1982 931 WB wana-be GTR race car
Back to top
View user's profile Send private message
ideola  



Joined: 01 Oct 2004
Posts: 15509
Location: Woodstock IL

PostPosted: Fri Sep 01, 2017 7:03 am    Post subject: Reply with quote

Kenodog wrote:
Au contrair. Casting is cheap and easy. As I mentioned before in a different thread I had a quote of $5,000 Cdn. to make a mold for casting new 931 exhaust manifolds. After that you simply pay a small set-up fee for each run and then by the pound for the raw material. Inconel 625 was quoted to me at $2/lb.

Mike's little part is ridiculously simple for a mold. The problem is finding enough people to cough up the dough to split the mold cost. Each unit after that would be peanuts though.


You'd be lucky to get 10 buyers, so just for the mold cost alone, that's $500 per piece. Maybe we have a different idea of cheap.
_________________
15 981 GTS | 88 924S SE | 82 931 Holbert | 82 931 Rallye | 81 937 | 81 Euro 931 | 81 Weissach | 80 US 928 | 80 US 931 '941' | 80 US 931 | 80 931 GTR | 79 Sebring | 78 D-Prod Replica | 78 w/D-Prod kit | 78 Poli-Form | 78 Limited Edition | 77 Martini
Back to top
View user's profile Send private message
Kenodog  



Joined: 25 Jun 2003
Posts: 2455
Location: Vancouver,B.C.

PostPosted: Fri Sep 01, 2017 7:08 am    Post subject: Reply with quote

While it may be true that my version of reality is different than most other peoples', I still maintain that you could sell brand new Inconel 931 manifolds all day long.

When someone is spending 30,000 Sterling on a ride they will not be abject to coughing up a measly 500 more for a new-made NOS manifold.

We don't ghetto stuff around here. Do it right is the quote of the day.




Leg
_________________
1979 Euro 931, Olive
1981 931, Sabine
2014 Mazda CX-5 (Kid's limo)
2008 GS500
1996 Dodge Caravan (DJV)
Back to top
View user's profile Send private message Send e-mail MSN Messenger
ideola  



Joined: 01 Oct 2004
Posts: 15509
Location: Woodstock IL

PostPosted: Fri Sep 01, 2017 7:34 am    Post subject: Reply with quote

Kenodog wrote:
I still maintain that you could sell brand new Inconel 931 manifolds all day long.

Sounds like a great candidate for a group buy.
_________________
15 981 GTS | 88 924S SE | 82 931 Holbert | 82 931 Rallye | 81 937 | 81 Euro 931 | 81 Weissach | 80 US 928 | 80 US 931 '941' | 80 US 931 | 80 931 GTR | 79 Sebring | 78 D-Prod Replica | 78 w/D-Prod kit | 78 Poli-Form | 78 Limited Edition | 77 Martini
Back to top
View user's profile Send private message
Mike9311  



Joined: 14 Dec 2004
Posts: 677
Location: Chicago-ish

PostPosted: Fri Sep 01, 2017 8:56 am    Post subject: Reply with quote

I always wished there was a way to create divided runners in a thinner walled manifold. Hopefully looking stock on the outside or at least close

Thought about it and started...but didn't take it much farther.


_________________
1980 931 ...off with the cobwebs
1982 931 Entwicklungsfahrzeug
1979 924 NA M471/M481 / ohne M650 Herausnehmbares Dach
0.5 1982 931 smashed parts car
1982 931 parts car?
1980 924 NA (R&D lightweight)
1982 931 WB wana-be GTR race car
Back to top
View user's profile Send private message
ideola  



Joined: 01 Oct 2004
Posts: 15509
Location: Woodstock IL

PostPosted: Fri Sep 01, 2017 9:30 am    Post subject: Reply with quote

Mike9311 wrote:


I'll take two.
_________________
15 981 GTS | 88 924S SE | 82 931 Holbert | 82 931 Rallye | 81 937 | 81 Euro 931 | 81 Weissach | 80 US 928 | 80 US 931 '941' | 80 US 931 | 80 931 GTR | 79 Sebring | 78 D-Prod Replica | 78 w/D-Prod kit | 78 Poli-Form | 78 Limited Edition | 77 Martini
Back to top
View user's profile Send private message
CÚdric  



Joined: 27 Aug 2004
Posts: 1751
Location: Sweden

PostPosted: Fri Sep 01, 2017 3:01 pm    Post subject: Reply with quote

Sign me up for a cast inconnel manifold:) ! I think you need to get closer to the euro scene and the historic racing/rallying guys, lots of dough in that world. And 931s have been popping up at alot of events. 25k pounds for new bdg engine for your ford escort, people obviously have money to spend. Maybe it would be a wise thing to get mittlemotor in Germany into the deal, I guess that's how you could get the volumes up and make such an idea into reality.
_________________
┤80 924 Turbo
Back to top
View user's profile Send private message MSN Messenger
Mike9311  



Joined: 14 Dec 2004
Posts: 677
Location: Chicago-ish

PostPosted: Fri Sep 01, 2017 11:03 pm    Post subject: Reply with quote

Seriously, for 500 I would take two, maybe 3 or 4.

I know mittlemotor wont be charging 500
_________________
1980 931 ...off with the cobwebs
1982 931 Entwicklungsfahrzeug
1979 924 NA M471/M481 / ohne M650 Herausnehmbares Dach
0.5 1982 931 smashed parts car
1982 931 parts car?
1980 924 NA (R&D lightweight)
1982 931 WB wana-be GTR race car
Back to top
View user's profile Send private message
Display posts from previous:   
Post new topic   Reply to topic    924Board.org Forum Index -> Performance Upgrades All times are GMT + 11 Hours
Goto page 1, 2, 3  Next
Page 1 of 3

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum


Powered by phpBB © 2001, 2005 phpBB Group