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Ideola Liquid to Air Intercooler Install
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Mike9311  



Joined: 14 Dec 2004
Posts: 668
Location: Chicago-ish

PostPosted: Sat Sep 02, 2017 12:34 am    Post subject: Reply with quote

So the Borg Warner turbine housings are investment cast stainless...what material exactly I have not figured out yet. Thinner, lighter, smoother, crack and high temp resistant...more retained heat...

ok...this didn't take long

http://kubotametal.com/alloys/heat_resistant/HK-40.pdf (HK30-HK40)

There are others but HK30 is what the EFR hot side is based on. Can be polished too.

We could make two styles, a 3 bolt and a four

Edit: CF8C-Plus stainless seems to be a better material

Edit: just laughing to myself how the modern world of running lean and hotter to save gas has caught up to my glowing red hot manifold of my '80 931....and how my threads either die or go off on tangents. I build an engine mount and we talk about billet heads. Now an intercooler inlet pipe and we talk about new exhaust manifolds If it wasn't for google we would never be able to search our topics.
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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
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WEASEL149  



Joined: 19 Aug 2005
Posts: 595
Location: UK, Sheffield

PostPosted: Sat Sep 02, 2017 2:47 am    Post subject: Reply with quote

I love threads like this, especially when the discussion goes off on a tangent .
I'm also a fan of the American way of machining/modding/hot-rodding, whatever you want to call it.

The 924 Turbo is creeping up in value in the UK and now quite rare so the current trend here is that everything has to be OEM/standard etc. From what I see it's gradually turning from an enthusiast car to an investment car. It's not really my scene I'm afraid to say.

So what I'm trying to say in a long-winded way is keep it up. By all means take a four foot cube of ally and machine it

I think I just need to move to the USA and buy me a proper pushrod V8 muscle car and have done with it. EU/UK bullshit strategies on cars are boring.
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1979 UK 932
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WEASEL149  



Joined: 19 Aug 2005
Posts: 595
Location: UK, Sheffield

PostPosted: Sat Sep 02, 2017 2:55 am    Post subject: Reply with quote

Going back to the Borg Warner investment cast turbine housings, they had problems with their earlier batches IIRC but can't remember why.
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1979 UK 932
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Kenodog  



Joined: 25 Jun 2003
Posts: 2445
Location: Vancouver,B.C.

PostPosted: Sat Sep 02, 2017 3:07 am    Post subject: Reply with quote

I would instead just make two different exhaust manifolds. One standard eith a 3-bolt flange and one a standard T-28 / T-30 4-bolt flange. Bolt on Inconel manifold with the option to direct bolt on a new double ball bearing T-28 would be the shizzle my nizzle.




Lei
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1979 Euro 931, Olive
1981 931, Sabine
2014 Mazda CX-5 (Kid's limo)
2008 GS500
1996 Dodge Caravan (DJV)
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Mike9311  



Joined: 14 Dec 2004
Posts: 668
Location: Chicago-ish

PostPosted: Sat Sep 02, 2017 4:13 am    Post subject: Reply with quote

Lately I have been trying to build things that can be bolted on but easily (ok not normally easy ) and returned to stock if the value rises or whatever.

By changing things like the motor mount, turbo mount and so forth. I am lightening things that are not typically lightened and I can return to stock if I want.

I have the luxury of owning a few so the '79 I will likely keep closer to stock, since it seems rare to begin with, but my '80 931, a four-bolter by birth, isn't something somebody wants for big dollar in the future, at least the way I am thinking now. Not to mention its history before '89...before me. So I can play with this 931.

The '82 Turbo, that is getting this inter-cooler, is somewhat of a rescue and I am trying to keep its integrity to a point.

I hope to have an update on the part by the end of today
_________________
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
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Mike9311  



Joined: 14 Dec 2004
Posts: 668
Location: Chicago-ish

PostPosted: Sat Sep 02, 2017 4:17 am    Post subject: Reply with quote

Kenodog wrote:
I would instead just make two different exhaust manifolds. One standard eith a 3-bolt flange and one a standard T-28 / T-30 4-bolt flange. Bolt on Inconel manifold with the option to direct bolt on a new double ball bearing T-28 would be the shizzle my nizzle.

Lei


At one point I wanted to machine (crazy) 3 or 4 pieces that I would then weld together. The last part having some sort of a v-band so that I could go 3 or bolt depending on the chosen turbo....I pushed this idea to the side
_________________
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
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Mike9311  



Joined: 14 Dec 2004
Posts: 668
Location: Chicago-ish

PostPosted: Sat Sep 02, 2017 4:45 am    Post subject: Reply with quote

To show that things do not always go smoothly, I am posting up a pic of a mid process weld up repair. There was a 'rapid' move by the endmill that should not have gone through the flange outer edge so I decided to weld it up before continuing. Not sure yet if it was my tweaking of 40K lines of code manually at the machine or a mistake from the CAM software. I'll sort that issue later....onward


_________________
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
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Mike9311  



Joined: 14 Dec 2004
Posts: 668
Location: Chicago-ish

PostPosted: Sat Sep 02, 2017 6:40 am    Post subject: Reply with quote

Sometimes its like watching water boil with a match but relentless just the same... I do slow it down though and turn off the coolant for the video

https://vimeo.com/232085086

Getting somewhere
_________________
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
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Mike9311  



Joined: 14 Dec 2004
Posts: 668
Location: Chicago-ish

PostPosted: Sat Sep 02, 2017 11:44 pm    Post subject: Reply with quote




_________________
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
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Mike9311  



Joined: 14 Dec 2004
Posts: 668
Location: Chicago-ish

PostPosted: Tue Sep 05, 2017 2:29 am    Post subject: Reply with quote

Updates..

Inner surface of the pipe only...see where I am going with this exercise?






_________________
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
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Mike9311  



Joined: 14 Dec 2004
Posts: 668
Location: Chicago-ish

PostPosted: Thu Sep 21, 2017 8:10 am    Post subject: Reply with quote

Oh you know where this is going after 92Forty1 is over...Billet Head

For now though. CNC porting the intercooler inlet pipe
https://vimeo.com/234741147
_________________
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
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Fasteddie313  



Joined: 29 Sep 2013
Posts: 1556
Location: MI

PostPosted: Thu Sep 21, 2017 10:14 am    Post subject: Reply with quote

You are really doing some awesome stuff..
This stuff is going to be amazing when you are done..
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80 Turbo - Slightly Modified
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Mike9311  



Joined: 14 Dec 2004
Posts: 668
Location: Chicago-ish

PostPosted: Fri Sep 22, 2017 12:28 am    Post subject: Reply with quote

Thank you and I hope so

This pipe though is being rushed for Dan's event tomorrow. Would like to see more of the outside finish to be from the CNC. the next one

I saw the other video postings from 19 days ago and was amazed at how interrupted I got.

Hopefully there will be more updates today
_________________
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
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View user's profile Send private message
Mike9311  



Joined: 14 Dec 2004
Posts: 668
Location: Chicago-ish

PostPosted: Sat Sep 23, 2017 1:08 am    Post subject: Reply with quote

Big mishap yesterday but salvageable. Mishap not shown.. we are almost finished with this one at least


_________________
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
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View user's profile Send private message
Mike9311  



Joined: 14 Dec 2004
Posts: 668
Location: Chicago-ish

PostPosted: Sat Sep 23, 2017 5:55 am    Post subject: Reply with quote

Down to the wire today...looks like I am mad maxing the intercooler radiator
_________________
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
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