Carl Fausett

For those of you with a 1985/86 32v 928, we now have both a Stage I (non-intercooled) and a Stage II kit (intercooled) available.

Although we developed our Stage I kit quite a few years ago, we never went on to work up an intercooler for Stage II. The challenge was the space envelope available for the intercooler, which, with the pipe-organ manifold, is quite limited.

This December we got our hands on a beauty of a 928 S3 5-speed so that we could take the time to engineer the best possible solution. Our intercooler is a thing of beauty, and flows extremely well, as you can see by the pictures and the HP results we achieved.

The 1985/86 32v 928 is reported at 288 BHP, but our test mule arrived with the cat already deleted and a non-standard exhaust, so we base-line tested it to get the accurate "before" number for this car and it came in at 306BHP (260 HP at the tire). A very healthy '85 32v 928.

After supercharging, it now made 460 HP at the engine (390 at the tire). What a blast to drive! This week the car goes back to it's home in Pennsylvania. We can ship this kit with instructions, or you can bring your car here for installation too.

More information is available at our webpage for this kit here:
https://928motorsports.com/parts/sta...harger_kit.php

Here is the YouTube video for it:
https://youtu.be/YqzL8t16or4

...and a few pictures

Enjoy!

davek9

Very nice numbers Carl, and clean looking installation

That intercooler is sweet

Thanks for keeping the S3 in the HP game

Dave

Chris Lockhart

Very nice!!! Kudos Carl.

V2Rocket

That intercooler is very clever packaging!
Nice work.

Carl Fausett

Thanks guys. We are very happy with the output from this kit - within a stone's throw of what the S4 makes...

Imo000

Very nice!!!! Are you willing to sell only the intercooler if someone needs one?

Carl Fausett

If one of our customers already has our Stage 1 kit on their 85/86 would like to upgrade to Stage 2, yes of course we would support that.

But these are kits and our parts are designed to work together. Things can get ugly really fast when parts are sold ala-carte and installed with mis-matching pieces from where-ever. I am reluctant to do that, as I am sure you can understand.

Imo000

No problem, I fully understand it.

928NOOBIE

That thing is freaking sweet Carl! WanT!!!

928S MN

Where and how does the water intercooler radiator and associated pump install?

I don't see it in any of the pictures.

Carl Fausett

We use a Dedenbear WP-3 water pump in our Stage II systems - its a little bit of over-kill, but it is an anvil and never fails. I found the Vortech pump they recommend to be a little wimpy and can be shunted by even just a little kink in the hose. The WP-3 is mounted inside the right front fender well behind the headlight.

Our early 32V Stage II kits used a heat exchanger and fan mounted right in front of the air conditioning condenser core, and it worked well. But now we mount the heat exchanger in the grille and get good cooling with no need for wiring another fan. It is an easier installation, doesn't hammer the alternator as much (no fan draw) and it doesn't block the AC condenser as much so engine temps stay lower and AC is colder. All pluses.

byrdman454

Is this kit just for 5-speeds? The reason I ask is that the location behind the grill is already occupied by the transmission cooler with automatics.

byrdman454

At first glance your pic looked like it was right up next to the grill, then I realized these parts were not installed on the car and only displayed for the photo.

If it is thin enough, it could go between the trans cooler and the A/C core like the old 928SP kits.

ptuomov

The intercooler looks good. Should flow and cool well, ifthe coolant is cool.

However, a question about the air cleaner. How much does that thing flow on the flow bench? Is the compressor pulling a big vacuum between the air cleaner and the compressor inlet?

Carl Fausett

We have wondered the same thing - "is that air filter assembly restrictive"?

This is how we tested it. We did a dyno pull with the air filter in place and got 390HP at the tire. Then we took the air filter off and did another dyno, this time the supercharger just inhaling through the 3" round hose.

Got 388HP at the tire that way, a negligible difference telling us that the air filter assembly is not restrictive at this power level. Consider also that as the engine heat-soaks, the dyno numbers will often come down from run-to-run, so this really was a non-issue.