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ideola
Joined: 01 Oct 2004
Posts: 15550
Location: Spring Lake MI
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 Posted: Tue Apr 24, 2012 12:47 pm Post subject: |
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I can confirm, NO HOLE REQUIRED in the hood or elsewhere. 
Now to start getting all the plumbing and ancillaries
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erstwhile owner of just about every 924 variant ever made |
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Nein37
Joined: 29 Dec 2009
Posts: 513
Location: New London, CT
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| Posted: Tue Apr 24, 2012 1:28 pm Post subject: |
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Looks great but the direct mount on the TB side will break without a rubber damper. Even an air to air unit stresses that mount point, add the water weight to the mix and its gonna be a problem down the road. However, it looks like you could weld the mount tab higher up and slip a rubber damper between there.
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1981 931 CGT replica, OEM CGT intercooler, .8 BAR WG spring, GTS Headlights, Innovative Wide band A/F, A/C delete, 16" Fuchs, Weltmeister 200lb lowering springs, Bilstein HDs front, Koni Sport rears. |
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ideola
Joined: 01 Oct 2004
Posts: 15550
Location: Spring Lake MI
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| Posted: Tue Apr 24, 2012 1:38 pm Post subject: |
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Duly noted. We'll see how it holds up. I think thin steel bracket will give before that thick-ass boss on the IC though. The concern with putting a rubber damper there is that you need some way to hold the IC outlet onto the TB, and a flex joint there will allow it to slip off, especially under high boost.
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erstwhile owner of just about every 924 variant ever made |
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Rasta Monsta
Joined: 12 Jul 2006
Posts: 11733
Location: PacNW
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| Posted: Wed Apr 25, 2012 1:17 am Post subject: |
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Wow, that is a great looking piece. Good job, Dan.
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Toofah King Bad
- WeiBe (1987 924S 2.5t) - 931 S3
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ideola
Joined: 01 Oct 2004
Posts: 15550
Location: Spring Lake MI
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| Posted: Wed Apr 25, 2012 1:39 am Post subject: |
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| Rasta Monsta wrote: | | Wow, that is a great looking piece. Good job, Dan. |
Thanks. The fit and finish is truly top rate. It just slid right into place, and was easier to fit than even the stock charge tube. I was impressed with how light and small it was when I first opened it...the photos are somewhat deceiving. Though it is necessarily thicker than the OEM unit to allow for the coolant circuit, overall, it is smaller and lighter than the OEM unit.
It's hard to appreciate the craftsmanship that went into the bends and cuts and welds on the inlet and outlet until you see it first hand. This was no trivial undertaking for the fabricator!
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erstwhile owner of just about every 924 variant ever made |
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brealytrent
Joined: 28 Dec 2008
Posts: 414
Location: Goldsboro, NC
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| Posted: Wed Apr 25, 2012 2:00 pm Post subject: |
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Looking good! Looking forward to the further progress!
Next on your list: a bolt-in water-cooled turbocharger kit
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1977 Porsche 924 - sold
1980 Porsche 931 - sold
1984 Porsche 928 'S2' Euro - sold
2016 Ford Fiesta ST - sold
2009 Porsche Cayman |
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Tim Cuddihy
Joined: 15 Dec 2004
Posts: 47
Location: Toowoomba, Australia
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| Posted: Wed May 02, 2012 10:35 pm Post subject: |
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I'm very interested in one of these and love the idea of not cutting holes in my car. Please PM through an idea of the pricing.
Thanks |
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WEASEL149
Joined: 19 Aug 2005
Posts: 595
Location: UK, Sheffield
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| Posted: Wed May 02, 2012 11:42 pm Post subject: |
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Excellent work Dan, love the air/water unit.
This has to be the ideal solution for anyone retaining the original inlet manifold and turbo location.
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1979 UK 932 |
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Grenadiers
Joined: 20 Feb 2007
Posts: 3222
Location: Nelson, WI & Prescott, AZ
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| Posted: Thu May 03, 2012 12:27 am Post subject: |
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Just need to source out a supply of Series II intake manifolds/throttle bodies! Or, maybe the fabricator might be able to set it up for the Series I as well?
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'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke |
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ideola
Joined: 01 Oct 2004
Posts: 15550
Location: Spring Lake MI
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| Posted: Thu May 03, 2012 2:53 am Post subject: |
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| Grenadiers wrote: | | Just need to source out a supply of Series II intake manifolds/throttle bodies! Or, maybe the fabricator might be able to set it up for the Series I as well? |
I have 2 or 3 spare S2 intakes and throttle bodies (as well as the S2 Throttle Body rebuild kits) available.
As for creating a version to work with the S1 setup, it would require a completely new fixture to be created, something I'm not interested in subsidizing...however, if someone *really* were insistent on keeping the S1 setup, I'm sure I could work with the fabricator to custom build one. My advice, however, would be to simply convert over to the S2 setup. The conversion is relatively inexpensive and easy to do.
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erstwhile owner of just about every 924 variant ever made |
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ideola
Joined: 01 Oct 2004
Posts: 15550
Location: Spring Lake MI
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| Posted: Thu May 03, 2012 3:17 am Post subject: |
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UPDATE: I've received most of the parts to do the installation, and will be providing details on everything required for the air and water circuits early next week.
In the meantime, I have confirmed all of the details and pricing.
These units are being fabricated exclusively for Ideola's Garage by Bell Intercoolers (as in Corky Bell, author of "Maximum Boost").
Introductory pricing for the unit as you see in the photos above is (conveniently enough) $937.00. This pricing is good for prepaid orders received from today through 30 May 2012, after which the standard price will be $997.00 (no exceptions, no extensions!!!). Lead time is a minimum of 4 weeks, not including shipment time. As some of you will note, this price is significantly lower than the initial indication of $1200.
Pricing does not include the necessary silicone couplers, brackets, or ancillary components required for the water circuit. I am hoping to put together a complete package with those components very shortly. I believe the total price tag for those components will be somewhere in the $300-$400 range (silicone couplers, t-bolt clamps, brackets, fittings, water pump, filler neck, water hose, and a small-ish radiator suitable for street application).
I will be adding the intercooler to my website within the next week or so, in the meantime, anyone interested in placing an order, please contact me via PM.
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erstwhile owner of just about every 924 variant ever made |
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Carrera RSR
Joined: 08 Jan 2010
Posts: 2312
Location: Somerset, UK
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| Posted: Thu May 03, 2012 6:04 am Post subject: |
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Out of curiosity Dan, how do you feel it will compare in performance terms versus a 951 FMIC install? With no extra boost etc, purely a bolt on, whats the anticipated bhp gain on a RoW S2?
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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
Then www.924board.org/viewtopic.php?t=31252 |
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ideola
Joined: 01 Oct 2004
Posts: 15550
Location: Spring Lake MI
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| Posted: Thu May 03, 2012 6:25 am Post subject: |
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| Carrera RSR wrote: | | Out of curiosity Dan, how do you feel it will compare in performance terms versus a 951 FMIC install? With no extra boost etc, purely a bolt on, whats the anticipated bhp gain on a RoW S2? |
Honestly, I have no way to know...and even when I get it installed on one of my "test mules", mine will be highly modified motors, so not a fair comparison to stock. What I intend to do is to do delta comparison on the 941 (closest to stock) with and without the IC. But I'm at least a month away from being able to get to the dyno (too much travel for my day job coming up in May  ).
All that said, the one thing to keep in mind is that the "cooling capacity" of this setup will be dramatically impacted by the size of the radiator you choose to install. The use characteristic for the 941 is 100% street driving, so for it, I am going with a relatively small radiator that will installed on the opposite side as the oil cooler. This will put it in direct airflow so it won't require the added complexity of a fan.
For maximum cooling, a MUCH larger radiator can be fitted, along with a fan to force airflow through the radiator. One could also add a supplemental coolant reservoir to increase the coolant capacity even more (and therefore the overall heat sink capacity). Such an arrangement will help stave off heat soak for longer periods of on-boost driving.
Keep in mind, this setup is intended primarily for a street car, not dedicated track driving. There's no way a W/A intercooler can compete with A/A setup on the track. But it will be far more efficient for street driving even with a small radiator. When I was working with Bell's design engineer, we used the figure of <300 BHP to size the core of the W/A unit. I also wanted it to be functional with as little complexity as possible, so I specified the design so that it does not require a fan or separate reservoir (although as noted, these can be added for increased efficiency/capacity).
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Grenadiers
Joined: 20 Feb 2007
Posts: 3222
Location: Nelson, WI & Prescott, AZ
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| Posted: Fri May 04, 2012 2:49 am Post subject: |
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Hey Dan, sorry to hijack the post on brackets, once again, but am looking for the parts numbers for items: 7,11, and 3. I"m going to cough up the cash and get the set.
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'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke |
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Power Tryp
Joined: 16 Apr 2009
Posts: 435
Location: Calgary, Alberta
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| Posted: Fri May 04, 2012 3:38 pm Post subject: |
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Ack! That's a good price for the limited time, I'm not sure if I can pull the money together that quickly.
I'll also need a series 2 intake and TB but those can come later.
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Melanie - 1980 931
NoName - 1980 931 (seeking rebuild)
Green tartan interior, you don't see that on a Civic. |
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