Gretch

Based on his design, I would say Mr. Murphy had the same thoughts.....

IMO, I would like to see a picture with the "hair dryer" in place.......How much lira do you think you have in this project so far?

dprantl

Can you explain how you managed to move the radiator? What does the radiator sit on? Do you have any pics from the bottom side?

Dan
'86 928S 5-spd w/LSD

Imo000

Jeff,

Thanks for the info. I should have spent a little more time on the reply cause the word "convinient" was not the right one for. It's evident that although turbo and SC are simmilar, they are vastly different when it comes to system design.

I think where I have the bypass valve now is ideal in a supercharger application, perhaps it's the opposite for a turbo. In any case, the elbow that the bypass valve is attached was just re-used from before the IC went in. Every black coloured boost pipe was re-used from the original setup, The only new pipe I used is still unpainted and you can see it at the bottom of the picture.

Now about the intercooler build,

I finished all the piping today. The two 90 degree rubber elbows came off a early 90's Ford F150 5.0L. These engines have sort of a dual throttle body intakes and the intake tubes they have are almost 2.5" in diameter. They are each over 3 feet long and are perfect for low boosted applications. I bought 2 sets (4 pipes) for $15. They even came with all the hose claps. The cutting of the elbows and including the installation took less than an hour. I had to use a heat gun to warm up the rubber (it's winter here) so it can slide them over the 2.5" pipes.

TOTAL intercooler build cost is $ 80 CDN ($65 for the IC and $15 for the two 90 elbows). The rest of the parts I already had, this incuds the flat steel stock for the rad. drop down brackets and all the other nuts/bolts.

If anyone needs any other pictures, this goes for the drop down brackets for the radiator too, just send me a PM. I took tons of it during the build and will eventually make a website so anyone can use my example for their own build.

I'm reaching the limit of my quota on rennlist so I had to delete one of the earlier pics to have this one uploaded.

Imo000

My limit is up and I can't post anymore pics, but I have a lot in other treads. Here is one of them. https://rennlist.com/forums/928-forum/203527-paxton-sc-instead-of-ac.html

The SC is right where the AC compressor and air pump used to be. The bypass vale I have is not mine, I borrowed it for testing, but will buy one before the spring. So including the cost of a new bypass valve ($100) total supercharger build cost is around $1150usd. I have a cost breakdown on this tread: https://rennlist.com/forums/928-forum/230334-first-time-at-the-drags-with-the-sc.html

Imo000

Here is an update on my intercooler project. I had to wait a few days after posting my last tread for the weather to break before I was able to take the car out for a test run. Test run ended with mixed results. The intercooler worked excellent. After several full boost runs the exit side of the intercooler was ice cold, also the boost pipe between the intercooler and the MAF was also very cold. This showed that the IC was doing what it was supposed to.

Now for the bad part. After the first run it became pretty evident that the IC can not flow enough to support 400hp. The pressure drop was around 1.5 – 2 psi across the board. However at full boost, near redline, the car felt just as fast as before the IC. Even with the IC chocking the motor the car was still a lot faster than before the supercharger but not as fast as without the intercooler. The only way to remedy this issue was to increase the flow capacity of the intercooler. This is where the purchase of a second Volvo intercooler came to play. I’ve read that the Volvo IC can support a max of 300hp, so two to of them should be more than enough. There is only one way to make this work and was to remove the end tanks and weld the two cores together then run them in parallel. This will double the capacity of the new IC and reduce the pressure drop to an acceptable level (0.5 – 1 psi). I bought a second IC from another local wrecking yard for $80cdn., a nice big aircraft grade aluminium sheet for another $5 and a couple sheets of bristle boards (for end thank mock up). The new end thanks will retain the original OEM shape but they will have double the width of the original.

Over the weekend, the mocking of the end tanks was completed, I also had enough time to cut the pieces out of aluminium. After the two IC cores were trimmed, I taped the paper end tanks to and dropped it into the car to see if the new IC will clear the hood. To my surprise it did without the need of any further modifications to the intercooler. It’s a tight fit but at least it fits, even the electric fan will fit without any issues. This week I’ll complete the cleaning and trimming of the aluminium tanks parts and take it to a welder. I don’t have a TIG welder so this step can not be completed by me.

I will post pictures once the IC is complete.

docmirror

You'll be running only 6PSI so I think you'll be okay. go to:

http://personal.linkline.com/dbarton...ml#intercooler

For specs on the intercooler. The temp drop you'll see is less than what they developed with the 2.4 motor, but any reduction is good reduction. they show about an 80% thermal efficiency, but take that with a grain of salt, I would still like a 194F delta in any turbo application.

The smaller area will actually help you with less noticable turbo lag. Besides, how often are you going to hold the throttle open for 10PSI of continuious boost? I would guess that you're turbo use would be occasional, and short term (> 30 sec).

Have it polished while it's out, that'll add at least 100HP

Doc

V2Rocket

reviving this dinothread

what were the results of using the volvo cooler? did it work better after doubling up the cores?