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Water-to-air intercooler installation - 81 931
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Mike9311  



Joined: 14 Dec 2004
Posts: 986
Location: Chicago-ish

PostPosted: Wed Dec 09, 2020 12:55 am    Post subject: Reply with quote

Packaging is exactly why it was installed on the '82

No body mods. No hood scoop on a narrow body. Just install and go. Just quick and easy to get an intercooler on a mid-range power car

Weight is an issue but that was the sacrifice to the above benefits
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1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA M650 Herausnehmbares Dach
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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chuck21401  



Joined: 20 Feb 2005
Posts: 322
Location: Annapolis, MD

PostPosted: Tue Dec 15, 2020 8:16 am    Post subject: Reply with quote

I ordered more 3/4" heater hose last week but it didn't arrive in time for the weekend. Was able to find 7' of 3/4" heater hose at Autozone. Had to try two locations to find it.

So the next step was to run the hose from the hot side of the heat exchanger to the in line filler. I did a test fit and quickly figured out that I needed to use a second 90 degree elbow rather than a straight fitting.



I routed the hose through a space in the valance.



Take a turn at the intercooler water pump.



Under the expansion tank



And up near the brake booster.


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1981 Porsche 931


Last edited by chuck21401 on Tue Dec 15, 2020 8:25 am; edited 1 time in total
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chuck21401  



Joined: 20 Feb 2005
Posts: 322
Location: Annapolis, MD

PostPosted: Tue Dec 15, 2020 8:24 am    Post subject: Reply with quote

Here is the in line filler connection



And the temporary boost controller set up. It's not elegant but it's functional.



I connected the wiring to run the fan and the water pump to test it out...I need to go back and tidy up that installation.

It took a while to fill up the system..one cup at a time...slowly. I elevated the inline filler a bit with a 2X4. That helped to get the air out of the system.



And after all of that....it worked! Up next: driving impressions.


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Fasteddie313  



Joined: 29 Sep 2013
Posts: 2130
Location: MI

PostPosted: Tue Dec 15, 2020 9:05 am    Post subject: Reply with quote

Looks nice!!

Keep a spare hose clamp or 2 with you and a tool for them in case ya blow one..
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Carrera RSR  



Joined: 08 Jan 2010
Posts: 2104
Location: Somerset, UK

PostPosted: Wed Dec 16, 2020 3:49 am    Post subject: Reply with quote

I'd suggest going dual port with that boost controller
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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
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chuck21401  



Joined: 20 Feb 2005
Posts: 322
Location: Annapolis, MD

PostPosted: Wed Dec 16, 2020 6:54 am    Post subject: Reply with quote

Carrera RSR wrote:
I'd suggest going dual port with that boost controller


I found this boost controller on Ebay a while back but still haven't figured out where to mount it. I can't seem to find a good spot under the hood and now I'm thinking it would look out of place in the cockpit. Maybe I'll hide it in the glove box. Or maybe I'll stick with the existing boost controller.





I'm also trying to remember the advantage of running a dual port waste gate. I know that the stock 931 WG can be configured that way. I have noticed that the boost controller I have now is very sensitive to adjustments. A 1/4 turn causes a huge change in the boost level. I have to barely move it to fine tune the boost.
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Carrera RSR  



Joined: 08 Jan 2010
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Location: Somerset, UK

PostPosted: Wed Dec 16, 2020 9:19 am    Post subject: Reply with quote

chuck21401 wrote:
Carrera RSR wrote:
I'd suggest going dual port with that boost controller


I found this boost controller on Ebay a while back but still haven't figured out where to mount it. I can't seem to find a good spot under the hood and now I'm thinking it would look out of place in the cockpit. Maybe I'll hide it in the glove box. Or maybe I'll stick with the existing boost controller.





I'm also trying to remember the advantage of running a dual port waste gate. I know that the stock 931 WG can be configured that way. I have noticed that the boost controller I have now is very sensitive to adjustments. A 1/4 turn causes a huge change in the boost level. I have to barely move it to fine tune the boost.


If your going to hide that, then it’s a complete waste. Just buy a cheap plastic air regulator
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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
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safe  



Joined: 18 Mar 2017
Posts: 210
Location: Sweden

PostPosted: Wed Dec 16, 2020 9:29 am    Post subject: Reply with quote

Carrera RSR wrote:


If your going to hide that, then it’s a complete waste. Just buy a cheap plastic air regulator


Yes, that goes between the seats or in the dash / center console
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Fasteddie313  



Joined: 29 Sep 2013
Posts: 2130
Location: MI

PostPosted: Wed Dec 16, 2020 9:40 am    Post subject: Reply with quote

I’ll hide it in my car for you

Where is this driving impressions post? Can’t wait!!
Go rip in it already!!
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morghen  



Joined: 21 Jan 2005
Posts: 8274
Location: Romania

PostPosted: Wed Dec 16, 2020 5:27 pm    Post subject: Reply with quote

Fasteddie313 wrote:
I’ll hide it in my car for you



I guess he wants to hide it from you lot, not that its not seen..he’s just afraid you turbo nuts will nick it
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Carrera RSR  



Joined: 08 Jan 2010
Posts: 2104
Location: Somerset, UK

PostPosted: Wed Dec 16, 2020 7:30 pm    Post subject: Reply with quote

morghen wrote:
Fasteddie313 wrote:
I’ll hide it in my car for you



I guess he wants to hide it from you lot, not that its not seen..he’s just afraid you turbo nuts will nick it



Yep....cash waiting
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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
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Mike9311  



Joined: 14 Dec 2004
Posts: 986
Location: Chicago-ish

PostPosted: Thu Dec 17, 2020 1:08 am    Post subject: Reply with quote

Word to the wise

If mounting that bad boy in the cockpit be careful on who you let drive. A dial like that is inviting and dangerous

Otherwise have at it
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA M650 Herausnehmbares Dach
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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chuck21401  



Joined: 20 Feb 2005
Posts: 322
Location: Annapolis, MD

PostPosted: Sun Dec 20, 2020 4:01 am    Post subject: Reply with quote

Fasteddie313 wrote:
Add the lower temp thermostat and lower temp rad fan operation to that mix, and you are in for a much healthier engine overall..


Coincidentally...I think my thermostat stopped working.

Everything was fine for the first couple of days. Then I noticed the temps creeping up just idling before going for a ride. Radiator hoses cold. Temp gauge high...usually it sits at the first mark on the gauge (80C?).

I ordered lower temp thermostat and fan switch from Paragon Products.

I've been reading up on the how-to procedure. Seems pretty straightforward.


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chuck21401  



Joined: 20 Feb 2005
Posts: 322
Location: Annapolis, MD

PostPosted: Sun Dec 20, 2020 4:38 am    Post subject: Reply with quote

chuck21401 wrote:
Up next: driving impressions.


First drive - I was actually surprised that the car started right up with no problems. I was expecting vacuum leaks...figuring that I would forget something. I also checked under the hood several times looking for coolant leaks...everything looked fine..

When I connected the manual boost controller I didn't change the setting. After the car was warmed up I gave it some gas to get into the boost. It's hard to say but it seemed like there was more lower end torque. Once out on the highway I did a couple of wide open throttle runs. Seemed to run well but the max boost was down from 8-9psi to 7-8 psi. I'm giving a range because it's difficult to see the exact reading from the driver's seat.

Second drive - I popped the hood and adjusted the boost controller. Gave it a 1/4 turn. Went for a drive and by second gear it was clear that the boost was too high...maybe 13-14psi...too much for where I want to be.

Third drive - Popped the hood and adjusted the boost controller again. This is getting old....maybe mounting it in the cockpit is a good idea after all? This time max boost was around 10-11psi. When I was happy with the boost level I drove over to my favorite straightaway. Basically there is a stoplight...then about a 1/4 mile straightaway....and then on to a long on ramp. I was able to wind out 2nd, 3rd gears and let off around 100mph in 4th. With the boost at 10+psi there is a transformation.

It's not clear to me if the intercooler increases hp/torque by itself...but combined with running higher boost levels the car seems a lot quicker to me.

I'm hoping that the intake temperature gauge arrives this week. I need to install that after I replace the thermostat and fan switch. I'll get some video to share intake temps while on boost.
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Mike9311  



Joined: 14 Dec 2004
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Location: Chicago-ish

PostPosted: Sun Dec 20, 2020 6:20 am    Post subject: Reply with quote

Its working! Nice!

So the boost being slightly lower is normal. You get a drop across the cooler. Everyone does to some extent and I am not surprised you feel a little bit more torque. I liken it to the feeling in a normally aspirated car on a cooler day. With the intercooler you will just have it more consistently.

When you hop out of the car, pop the hood and put your hand on the exhaust side of the intercooler and then the throttle body side. You should notice a big difference. Of course we will all wait for the gauge to arrive and your testing but its a neat little check.

Awesome
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1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA M650 Herausnehmbares Dach
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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