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Ideola Liquid to Air Intercooler Install
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Mike9311  



Joined: 14 Dec 2004
Posts: 652
Location: Chicago-ish

PostPosted: Sat Sep 23, 2017 7:51 am    Post subject: Reply with quote

Done! Ok not the entire install yet but the part is done. Will post more video's later


_________________
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: 652
Location: Chicago-ish

PostPosted: Mon Sep 25, 2017 4:56 am    Post subject: Reply with quote

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 ...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 26, 2017 8:15 am; edited 1 time in total
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Fasteddie313  



Joined: 29 Sep 2013
Posts: 1489
Location: Not Detriot - NMI

PostPosted: Mon Sep 25, 2017 7:46 am    Post subject: Reply with quote

Amazing!!
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1980 931S - LSD - FMIC - GTS fuel - hobby
95 M3 manual coupe - summer DD
06 X5 3.0 auto - winter DD
01 RS25 coupe - 90% Retired
06 MDX - bought for mom to DD
81 Rambler BBC 454
97 Tercel long retired/sitting
77 gs750 - 95 300ex - 89 blaster
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Carrera RSR  



Joined: 08 Jan 2010
Posts: 1533
Location: Somerset, UK

PostPosted: Mon Sep 25, 2017 7:04 pm    Post subject: Reply with quote

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.
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1980 931 - forged pistons, Piper cam, CGT turbo, 951 ducted FMIC, custom intake, Mittelmotor dizzy & cam pulley, H&S exhaust, GAZ Gold, Fuch'ed, Quaife LSD
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: 652
Location: Chicago-ish

PostPosted: Tue Sep 26, 2017 6:19 am    Post subject: Reply with quote

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 ...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: 652
Location: Chicago-ish

PostPosted: Tue Sep 26, 2017 8:13 am    Post subject: Reply with quote

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 ...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: 652
Location: Chicago-ish

PostPosted: Tue Sep 26, 2017 10:20 am    Post subject: Reply with quote

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 ...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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Dutch924-racer  



Joined: 23 Jul 2007
Posts: 1000
Location: The Netherlands

PostPosted: Tue Sep 26, 2017 4:32 pm    Post subject: Reply with quote

very nice work!

Where did you hook up the water lines/ return line in the system ?
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937 trackday car
Series 2 engine
951S turbo and intercooler
937 DITC
Fast road camshaft
Forge recirculation valve + boost controller
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Carrera RSR  



Joined: 08 Jan 2010
Posts: 1533
Location: Somerset, UK

PostPosted: Tue Sep 26, 2017 9:12 pm    Post subject: Reply with quote

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, CGT turbo, 951 ducted FMIC, custom intake, Mittelmotor dizzy & cam pulley, H&S exhaust, GAZ Gold, Fuch'ed, Quaife LSD
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: 652
Location: Chicago-ish

PostPosted: Wed Sep 27, 2017 12:14 am    Post subject: Reply with quote

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 ...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: 652
Location: Chicago-ish

PostPosted: Wed Sep 27, 2017 6:26 am    Post subject: Reply with quote

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 ...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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Paulyy  



Joined: 05 May 2014
Posts: 87
Location: Melbourne

PostPosted: Thu Sep 28, 2017 1:02 am    Post subject: Reply with quote

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.
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http://www.924board.org/viewtopic.php?p=384410#384410
951 - 400whp.
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ideola  



Joined: 01 Oct 2004
Posts: 15489
Location: Woodstock IL

PostPosted: Thu Sep 28, 2017 1:10 am    Post subject: Reply with quote

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.
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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
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Paulyy  



Joined: 05 May 2014
Posts: 87
Location: Melbourne

PostPosted: Thu Sep 28, 2017 1:32 am    Post subject: Reply with quote

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.
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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: 72
Location: South West Queensland, Australia

PostPosted: Tue Oct 10, 2017 8:24 pm    Post subject: Reply with quote

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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