924Board.org

[bear924]

Hello ideola,

I've been eagerly awaiting updates on your installation, any additional news yet?

Thanks

[ideola]

[Rasta Monsta]

Here is one take on the pump/heat exchanger:






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Toofah King Bad

• WeiBe (1987 924S 2.5t) - 931 S3

[bear924]

Hello Rasta,

Your photos highlighted the need for a filling cap, thanks.

Do you happen to know your pump flow rate and/or heat exchanger cooling capacity?

I appreciate your input, I look forward to hearing about your finished product.

Thanks
Wayne

[nwns]

Have you had this mounted and running yet Dan?

Do I need anything else other than the cooler, install kit and bracket to mount it up?

Also what's the shipping charge to the UK?
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Pete

[ideola]

Unfortunately, the Club Sport motor has to come out due to an oil pressure issue. I completed installation of the air circuit, but never completed the water circuit, and have not run the motor yet with the IC.

Not sure if you've seen it or not, but I finally got around to documenting the complete kit required for installation, which is now available on my site. You shouldn't need much if anything other than the stuff listed in the kit:

• (4) 2.25" T-bolt clamps
  
• (2) 2.25" silicone 45° elbows (black)
  
• 3/4" Remote inline filler cap
  
• Bosch intercooler pump and harness
  
• (4) brass 1/2" NPT Male to 3/4" barbed 90° elbows for intercooler or heat exchanger
  
• (2) brass 1/2" NPT Male to 3/4" barbed straights for intercooler or heat exchanger
  
• 10 feet of 3/4" flexible fluid lines
  
• (6) 3/4" worm gear clamps
  
• 10-row radiator (11.5" x 5.75" x 2")
  
• 2.25" cast aluminum tight radius 90° elbow

The Bosch pump will draw between 2.5-3.5A and is rated at 317GPH. I have a PDF with the Bosch cut sheet somewhere, but this is the pump that was recommended to me by Bell.

Note that the kit includes a remote inline filler with cap, eliminating the need to put one directly on the IC or the radiator. This approach allows the filler to be placed anywhere the end user chooses directly in line with the 3/4" flex hose.

The "basic" kit includes the smallest radiator, which will fit neatly under the horns (in the opposite location as the OEM 931 oil cooler), taking advantage of the vented nose valance. I KNOW FULL WELL that this radiator is not very big. I have a full range of radiators available, which can also be enhanced with fans and a remote reservoir. These measures will allow each customer to "tune" the heat sink capacity of their installation based on how they plan to run the car.

For starters, on my personal installation, I am only concerned about street driving on the Club Sport (i.e. short boost runs) where heat soak should not be an issue. When I get serious about track events, I'll increase the rad size first, and then look at other enhancements like a fan and remote reservoir as circumstance dictate. If you're considering one of these, we should discuss the rad so we can size it appropriately for your intended use.

As for shipping to the UK, I'll weigh all the components tomorrow so I can give you an idea on what it will cost.
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erstwhile owner of just about every 924 variant ever made

[nwns]

Thanks Dan
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Pete

[ideola]

Before I start disassembling things to pull the motor, I snapped some pix of the intercooler with the air circuit plumbed in. This is using the kit listed on my site (and above). The silicone couplers are available in black, red, and blue. My supplier only had red in stock when I ordered...I wanted black, but was too impatient to wait. These pix show the two 45° silicone couplers and the 90° tight radius cast alu elbow. So the connection is turbo outlet to 45° silicone elbow to 90° cast elbow to 45° silicone to IC inlet. All components are 2.25" I.D. Pretty straight forward. When I take the IC out, I'll leave the silicone / cast elbow assembly together and snap another pic or two so you can see better how to orient the couplers.




Here is a pic of the Bosch pump:


And here is a link to the product spec sheet:
http://garage.ideola.com/downloads/BOSCH-0392022002.pdf

I was also able to find a better price on the pump, which allowed me to reduce the basic install kit from $370 down to $350. I've posted these new pix, links, info, and pricing on my website.
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erstwhile owner of just about every 924 variant ever made

[Carrera RSR]

Looks like a good kit Dan. When can we expect to see some dyno printouts of adding this kit to a RoW car? What's the estimate? It's a lot of money without tangible results. However a good buy with performance comparable to CGT or GTS
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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

[ideola]

[nwns]

I finally installed my chargecooler, it's ace.

[/img]
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Pete

[leadfoot]

Oh o... Now tou have to polish all the other aluminium... Looks sweet
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1981 ROW 924 Turbo -
carbon fiber GT mish mash
LS1 conversion in progress...

[Rasta Monsta]

Looks good! What are you doing for heat exchanger?
_________________
Toofah King Bad

• WeiBe (1987 924S 2.5t) - 931 S3

[ideola]

Pete, thanks for sharing the install pix. I realized that I still haven't taken pix of the completed installation on the Club Sport. I'm going back to MI this weekend, if I remember, I'll try to snap some pix while there. It looks like you took an essentially identical approach to the water lines as mine.
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erstwhile owner of just about every 924 variant ever made

[jbizzle78]

Are these intercoolers still available? I’m interested in one.