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Mike9311
Joined: 14 Dec 2004 Posts: 1678 Location: Chicago-ish
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Posted: Sat Sep 23, 2017 6:51 am Post subject: |
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Done! Ok not the entire install yet but the part is done. Will post more video's later
_________________ 1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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Mike9311
Joined: 14 Dec 2004 Posts: 1678 Location: Chicago-ish
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Posted: Mon Sep 25, 2017 3:56 am Post subject: |
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Last video...Personally I think its the coolest. In this configuration the machine made quick work of the second side. A bit of hand finishing and it was ready
https://vimeo.com/235077043
Late night thrash and we didn't make it. At least Dan is beyond kind and let us drive a couple of his cars to enjoy the Toofapalooza event yesterday.
Looks totally stock right? Like Porsche meant it to be there (not billet). Like I said CarreraRSR inspired me. Few things need to be fixed sorted and maybe moved around...oh and the zip tied intercooler radiator strapped under the bumper will be changed after some driving .... complete cheese but it will work for some testing
_________________ 1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car
Last edited by Mike9311 on Tue Sep 26, 2017 7:15 am; edited 1 time in total |
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Fasteddie313
Joined: 29 Sep 2013 Posts: 2596 Location: MI
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Posted: Mon Sep 25, 2017 6:46 am Post subject: |
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Amazing!! _________________ 80 Turbo - Slightly Modified |
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Carrera RSR
Joined: 08 Jan 2010 Posts: 2309 Location: Somerset, UK
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Posted: Mon Sep 25, 2017 6:04 pm Post subject: |
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Looks nice and tidy install, well done. What I have learned is that a textured / rough surface expels heat quicker than a smooth surface, more surface area to air. So I would consider the charge cooler to be aqua blasted for a nice matt surface. Depending on post cooler intake temps in mixed road conditions, I would also consider a bonnet scoop to give the cooler the best opportunity to cool despite the water cooling. Will work as a chimney for heat in slow traffic as well as additional cooling when moving. 20% More BHP = 20% More heat. Good luck with finishing it up. Would be nice to see what the final result is regarding bhp. Not sure anyone has done a pre/post bhp test on a dyno? Its often a discussion in the UK of TMIC v's 944 IC v's charge cooler bhp results. _________________ 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 |
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Mike9311
Joined: 14 Dec 2004 Posts: 1678 Location: Chicago-ish
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Posted: Tue Sep 26, 2017 5:19 am Post subject: |
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Thanks everyone
I am curious too about the power. Will look into suggestions and such once we tackle an issue the car developed
Rough running when started hot. During the install we also switched radiators so at start up we bled and so forth. Everything seemed fine but after turning it off and restarting it ran rough. Hard start and missing 1-2 cylinders. I bet if I fired it up today cold it would act fine. Had this issue before but we thought it was licked...guess not. Will be running down the troubleshooting list as soon as we get a moment or two _________________ 1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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Mike9311
Joined: 14 Dec 2004 Posts: 1678 Location: Chicago-ish
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Posted: Tue Sep 26, 2017 7:13 am Post subject: |
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This is why you call it a night sometimes and don't just keep pushing until 1:30AM. For whatever reason the intercooler wasn't seated correctly so we had a total vacuum/boost leak at the throttle body We just didn't see it that night. Had that intercooler on/off so many times too. Just the last time we didn't get it right
Going to redo and try again...unreal
Edit...or I blew the o-ring seal out. Didn't have the one screw holding the intercooler to the bracket by the throttle body _________________ 1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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Mike9311
Joined: 14 Dec 2004 Posts: 1678 Location: Chicago-ish
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Posted: Tue Sep 26, 2017 9:20 am Post subject: |
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Wooo hooo! She rips
What a rookie move. Re-seated the throttle body o-ring and 'put a bolt' into the neighboring bracket and perfecto
Man, can't wait to raise the boost and finish the intercooler radiator mounting the right way.
....and this car finally handles. The top rubber shock mounts replaced with new and she finally handles the way I remember.
Intercooler works awesome! After a while I noticed the hot side was hot the the throttle body side was cold ...sweetness _________________ 1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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Dutch924-racer
Joined: 23 Jul 2007 Posts: 1077 Location: The Netherlands
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Posted: Tue Sep 26, 2017 3:32 pm Post subject: |
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very nice work!
Where did you hook up the water lines/ return line in the system ? _________________ 937 trackday car
Series 2 engine
951S turbo and intercooler
Fast road camshaft
Forge recirculation valve + boost controller |
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Carrera RSR
Joined: 08 Jan 2010 Posts: 2309 Location: Somerset, UK
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Posted: Tue Sep 26, 2017 8:12 pm Post subject: |
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Warning. Once boost has been turned up to 1bar there is no returning to stock boost!!!!!!! Soon you will understand that statement _________________ 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 |
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Mike9311
Joined: 14 Dec 2004 Posts: 1678 Location: Chicago-ish
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Posted: Tue Sep 26, 2017 11:14 pm Post subject: |
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Oh I have already tasted the 1 bar ohhh so long ago in my S1.
1991-ish I had the first gen HKS EVC boost controller (still have it). Since I could press a button to get immediate boost, I would leave it at stock levels and simply press the button when needed. A really nice way to taste the difference. It also had the very 1st IFC GTS headlight conversion and a 944 style front end (also early IFC)
Its this car below. I even purchased a 944 T intercooler probably 12-15 years ago but was never really satisfied with installation ideas until I saw your way. So this will be the route with this car. I am not saddened by cutting into it (it was only a 4 lug to start). It has been sitting in storage far too long while I decide what to do..second pic won't post full size..1st picture just disappeared... .Edit: Flickr is up to something today and it isn't good! Yup confirmed they took away the 1st photo full size as well...Test me yahoo...test me...I can host me own stuff...anyway back on topic
Testing a wheel choice after fitting 5 lug suspension
The lines are a work in progress. For now, one comes from the rear and runs along side the intercooler (exhaust/turbo side) which I am not liking right now due to heat soak. I didn't have enough line to get the job done that night so it might get sleeved or rerouted. The other line is straight out of the front of the cooler and it loops driver side and down. Pump is mounted on a custom aluminum stand off from the horn mounts or at least right in that area. Its a Bosch pump with an OEM mount (Ford?). No drilling required and a nicely damped mount. The heat exchanger is from a Toyota Prius. Its the Inverter Heat Exchanger. Light, cheap, and very effective. Only problem...2-3 inches (50-80mm roughly) too long so fitment has been an issue. I have several spare bumpers and one is being tweaked to house the heat exchanger. For now its strapped down low on the valance face with zip ties (completely temporary I promise). It may get a small fan as well. I'll have to post a pic of the cheesy heat exchanger install.
(Edit: I should add we have the wastegate hooked up to a custom bung welded on the back of the intercooler. Nothing like the thrill of modding a brand new part with drilling and welding)
I was really surprised yesterday how quick it felt at stock boost since it was such a hot day. I was half expecting not to feel anything. I figured I'd lose boost and gain a bit due to cooling (zero sum gain). Need to hook up the gauge, the boost controller, and AFR next.
Still a small issue remains as well ...fuel pump runs when it shouldn't. Need to continue the diagnostics _________________ 1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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Mike9311
Joined: 14 Dec 2004 Posts: 1678 Location: Chicago-ish
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Posted: Wed Sep 27, 2017 5:26 am Post subject: |
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You can tell I am a S1 guy... The DITC connector wasn't on very well. Even after all that work fixing the wiring under the dash, one would think it would get checked.
Going to sleeve the hose running on the exhaust side too _________________ 1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA ohne 650 mit 471
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car |
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Paulyy
Joined: 05 May 2014 Posts: 87 Location: Melbourne
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Posted: Thu Sep 28, 2017 12:02 am Post subject: |
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Cool little project. I love touches like that.
Also where did you get the Water to air cooler from? And what the HP rating? Ive been thinking of going this route because i dont think i'll have enough room for a large IC infront of the radiator. _________________ 924 - Race car project in the works.
http://www.924board.org/viewtopic.php?p=384410#384410
951 - 400whp. |
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ideola
Joined: 01 Oct 2004 Posts: 15548 Location: Spring Lake MI
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Posted: Thu Sep 28, 2017 12:10 am Post subject: |
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Paulyy wrote: | where did you get the Water to air cooler from? And what the HP rating? |
http://garage.ideola.com/prod-BoostSolutions.html
The intercoolers are rated for 600+CFM of airflow, so good for at least 450BHP. Although you will likely detonate long before then unless you go full-stand-alone EFI / EMS. The liquid to air version is nice because it is "expandable"; you can increase the capacity of the coolant circuit by adding a larger heat exchange (many options available), adding a fan to the heat exchanger, and adding a dedicated expansion tank. The more liquid you have, the longer boost runs you can do before heat soak. _________________ erstwhile owner of just about every 924 variant ever made |
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Paulyy
Joined: 05 May 2014 Posts: 87 Location: Melbourne
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Posted: Thu Sep 28, 2017 12:32 am Post subject: |
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ideola wrote: | Paulyy wrote: | where did you get the Water to air cooler from? And what the HP rating? |
http://garage.ideola.com/prod-BoostSolutions.html
The intercoolers are rated for 600+CFM of airflow, so good for at least 450BHP. Although you will likely detonate long before then unless you go full-stand-alone EFI / EMS. The liquid to air version is nice because it is "expandable"; you can increase the capacity of the coolant circuit by adding a larger heat exchange (many options available), adding a fan to the heat exchanger, and adding a dedicated expansion tank. The more liquid you have, the longer boost runs you can do before heat soak. |
Thanks Dan,
I was hoping it was a generic one as i wanted to see other sized intercoolers. it is a nice stock replacement unit though.
I'll start a thread for a discussion, dont want to hijack. _________________ 924 - Race car project in the works.
http://www.924board.org/viewtopic.php?p=384410#384410
951 - 400whp. |
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bear924
Joined: 26 Jul 2005 Posts: 95 Location: South West Queensland, Australia
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Posted: Tue Oct 10, 2017 7:24 pm Post subject: |
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Mike,
Impressive work. I will shortly be installing my A/W intercooler, your post has certainly helped drive my wrenching juices. Well done. |
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