Good news is my second I/C core came in the bad news is I have to Self quarantine for a week awaiting a surgical procedure next Friday. Always something. I was up at my friend Pino's shop yesterday and I was distracted by a prototype 912 my friend Dom will be photo documenting for 000 magazine. He did discuss stopping by to photograph my progress on the Blue Meanie for a potential article for Excellence magazine but we will see. The last article for Excellence I was in was shot nearly 2 years before it was published. So for now I will be on hold yet again.

 

Anthony, reach out to AIM Performance within 50 miles from you in Middlesex Joe has a 993 tt close to 1000 whp and exceeds 200 mph but looks like a stocker.

 

I see he uses a dynojet. Normally we see 18% less on our mustang vs a dynojet but they are just numbers. In either case this is not about max power but a smooth overall usable power curve I can track without worries. My car will max out at around 170MPH but that is due to the gearing and I will probably never see that even on track.

 

As I sit here at home in self isolation. Covid has just delayed everything.

George is working on the cooling system in my absence. He mounted the tank and began running the lines through the bulkhead. His way is a little different than mine but there is more than one way to skin a cat.

Figured I would post some for now. Hopefully will be up and about by next week to continue.

Once everything is dry fit it will be removed and finished for now we just want to get it all sorted. Track season is quickly creeping up on us.

Tank with beginnings of the lines and the modified tip oil cooler we are using for the turbo radiator with its own fan. The water pump is mounted to the floor boards using a bracket George 3D printed. This will be made out of a better plastic for final fitment. I also plan to run the oil cooler lines differently as I am not a fan how they were initially run.

Interestingly they had a GT2 in the shop yesterday and Porsche used a similar cooler setup without us knowing.

 

Just reading through your thread. Drool worthy.
Can't wait to see it all come together.

 

So I am alive which is good although I will be out of commission for a while.

We have been working on the flow characteristics of the intercooler using a flow simulator and have learned quite a bit. Seems the most restrictive area which is what we expected, the end tanks. The straight design IC design used by the factory for the 993 is far from ideal and we have a design we feel will flow far better. I need to see how I can make the input of the end tanks more of a conical shape vs a straight pipe into the tank. I will try to make a part by bending aluminum plate. Of course if I had the foundry or a CNC machine at my disposable it would make for a better design and end product but I think I can get close by bending and welding. The IC should be a unique piece and we found a way to reduce flow restrictions by 7ths or 2.44 times less pressure drop. All this helps in the end. I believe we can improve on those numbers with a revised end tank.

I will post more soon. This is not the design we are using but a starting point. The end result should be quite interesting.

 

Looks like you are on your way to building an intercooler to rival a Secan unit. Nice work.

 

Thanks

The Secan units I always considered the gold standard. Not much different than Motec for tuning but like everything technology is quickly catching up and so much more is available to work with today. I find the pricing of the Secan IC hard to believe. I always knew they were expensive but ouch.

If the facts are true these new Garrett units should be better at a fraction of the cost. After many simulations and studying the 993 IC we do not like the straight through design as I posted above. The end tanks make a difference but not enough to go crazy over and we found placing a baffle in the middle improves the flow considerably. The stock 993 design when using the flow simulator shows a lot of cross flow and turbulence over the cores and by placing a divider plate will improve upon the efficiency and reduce cross flow. We have a plan to build something a little unconventional but seems to be the best we can do with the limited space and the size of the cores. If they made them in a slightly smaller width that would be great but they don't. So as with everything, a compromise. These will easily handle 700 WHP, although I don't plan to push it that hard so it is more a learning curve and I enjoy playing with stuff like this.

Interestingly I had to do calculations and flow design studies on gating of the castings I made prior to production. Having tools like this back in the day would have been very helpful although after years of designing gating systems I was able to get darn close to perfect by just getting a feel of how metal flowed through the mold by mistakes I learned from. I guess that is experience for you. It is interesting that I can look at what we are building and have a pretty good feel of what will work and what wont from my prior life.

We did play with the proto design and I read someplace Bruce Anderson said it was 90% efficient. I guess he didn't have programs like this to test them as we found it a bit lacking.

We will start fabrication on the unit soon and will post pictures when it is finally welded together. Then finding a way to mount it for easy R&I and making the throttle body connections will be a challenge. I will need to modify the plenums to mount the IC and use it to hold them together under boost.

Slowly getting there. Once everything is fitted it will be dismantled and then the finish work prior to starting her up which is still a long way away. Not too long I hope. 🤞

 

So I am still alive. LOL The surgery really took its toll and I am moving slowly. Just finally getting around to sleeping again after nearly 2 weeks. It really takes its toll.

I was able to work on some simple things like finishing the oil lines. This is what I have so far. The factory oil return line needs to be modified so nothing rubs.







After a lot of time simulating different IC configurations we decided on this as our final shape. The thing is huge and weighs 30 pounds hanging off the back end but these are the compromises of a build like this. It is welded but it is not finished yet. I will post pics of it welded when finished. The unit needs to be on the angle to work with the tail, It is quite tight under all that and having the 9 vs 6 slot wing makes all the difference. It is not conventional but I don't think we can get more out of it unless I CNC side tanks although the simulations show minimal gains vs expense. I can easily access everything I need to track side which was an initial concern. I need to make some brackets to support it securely to the engine carrier. Once this is done the engine can come back out and all the finishing work can be done out of the car. I also found the perfect coil pack to fit my engine and will be eliminating the distributor soon. When it is all done I will paint it black using radiator paint. I think it will look better that way.

 

Things aren't moving as quickly as I would like or maybe it is just me. The IC welding is done. I wanted it to look clean which proved to be more work than expected. (Imagine that) It is far from perfect but will do the job. After cleaning the welds it was tapped with a schrader valve and pressurized to 50 PSI to test for leaks. Well that proved to be a good call as I found a bunch of very small leaks that needed additional welding and cleaning. I don't think they would impact performance but don't want anything to crack under pressure or heat cycling so I believe it will be fine considering max pressure from the turbos will be 14 psi but I doubt we will be close to that.

So now I can make the pipes for the turbo connections and make the opening for the plumbing to the throttle body. Then i can make the mounting points and paint.

 

Labor of love.

Are you really going to take this thing to track and race it when you’re done? It looks way too pretty

 

Thx

In hindsight maybe I should have gone the less track focused route with this build but it was built with the intention of tracking it. I don't believe in using cars with roll cages on the street, it can be hazardous without a helmet. I do plan to build another but that will be a N/A street build.

The beauty of a build like this is if it gets damaged it can always be fixed. I did concours this at a zone event and took first in its class against some beautiful 73RS's and other rare cars a number of years back with the old engine. I enjoy the build process as much as I do the drive. Having the opportunity to hang out at a shop all day and playing with either this or any number of exotics all day long is one of my dreams come true. The other is not so PG and requires me being young again going back in time and hanging out at Hefner's playground. I guess this will have to do. LOL

 

Any updates on the build?

 

I had put the project on hold due to some health issues and other projects. I purchased the other 964 track car (affectionately called the **** Box) and had been using that for the time being. I had installed a numeric shifter in it to help on track and fixed some minor leaks I inherited from prior shoddy work. This took the pressure off the Blue Meanie and my new completion date is February. 🤞

Ironically you ask this today as the engine is slatted to be dropped this morning so the final fit and finish of the IC, intake and coil packs can be finished with it out of the car. Engine out makes for a much easier process. I had been working slowly on my slick top project my 93 C2 now getting new carpet and the **** Box needed some oil leaks repaired.

So this little progress is all I have for now and pics of the other cars. I need to update those threads as well. I had been busy with PT as I lost feeling in my left hand due to a herniated disc in my neck so my progress has slowed while taking care of it.

I should have some news in the upcoming weeks possibly something by the end of the week if all goes to plan.




Minor but actual progress. IC is mounted and will hold the intakes together under boost.

As it will sit lower bracket still needs some work but enough done to drop the engine.

C2 finished paint and slick top. New headliner installed and carpeting currently in process.

**** Box now has a numeric shifter and oil leaks are all fixed. Amazing how much attention this car gets for what it is.

At the Glen with my son's cayman S

Turbo on display at the Bridge 9-18-21

 

I want a ride on the Meanie when done brother man!