Just toying around in the Shop - moved past FMIC for 944 Intercooler in 968
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As part of the never-ending saga of my 968T project, I've finally gotten around to cypherin' on the subject of incorporating an Intercooler into the 968 body.
Since I do not know how to add pics between sentences/paragraphs, I'll just add them at the end.
Since my project is about 1100 miles away in the Midwest, where its been hanging on a lift in a heated garage, it's kinda hard to just go out tot he garage and start figuring things out - like where/how to incorporate an Intercooler without doing some serious front body modifications and then there is the whole second hood latch or hood pins (which I think look out of place on a P-car) method to secure the hood. Obviously do-able, but not without a fair amount of noodling.
So, I sought out a working model. Found a front end from Oklahoma Foreign. Mounted it to an old desk and viola - working model that I can tinker with. Added a lower support to serve as the maximum lower edge to determine dimensions for the intercooler.
Next, looked up Air to Air Intercooler fab - found a site with decent info (http://www.bellintercoolers.com/) and started researching what would fit best in the available space and what power level it will support.
Had some foam board left over from a previous project and basically finished up the initial model today.
Using core that is 4.5"Dx7.9"Tx12"W (rated for just over 600 CFM). End tanks are 3"Wx7.9"T with a 3" radius on the bottom edge. Inlet/outlet tubes are modeled for 2.75"ODx0.065" wall aluminum tubing (which should match up nicely with another future project - custom intake using 65mm TB). Rising first 1" from the upper tank end edge, then turning at 35 degree angle toward the engine.
Although not the same as the 'factory' 968T, and may not be as efficient as the 944T intercoolr - it seems to fit well with minimal amount of metal work (I spent probably about 3 hours hour cutting/grinding the holes) that doesn't jeopardize frame rigidity or require reworks of the hood latch assembly.
Since I do not know how to add pics between sentences/paragraphs, I'll just add them at the end.
Since my project is about 1100 miles away in the Midwest, where its been hanging on a lift in a heated garage, it's kinda hard to just go out tot he garage and start figuring things out - like where/how to incorporate an Intercooler without doing some serious front body modifications and then there is the whole second hood latch or hood pins (which I think look out of place on a P-car) method to secure the hood. Obviously do-able, but not without a fair amount of noodling.
So, I sought out a working model. Found a front end from Oklahoma Foreign. Mounted it to an old desk and viola - working model that I can tinker with. Added a lower support to serve as the maximum lower edge to determine dimensions for the intercooler.
Next, looked up Air to Air Intercooler fab - found a site with decent info (http://www.bellintercoolers.com/) and started researching what would fit best in the available space and what power level it will support.
Had some foam board left over from a previous project and basically finished up the initial model today.
Using core that is 4.5"Dx7.9"Tx12"W (rated for just over 600 CFM). End tanks are 3"Wx7.9"T with a 3" radius on the bottom edge. Inlet/outlet tubes are modeled for 2.75"ODx0.065" wall aluminum tubing (which should match up nicely with another future project - custom intake using 65mm TB). Rising first 1" from the upper tank end edge, then turning at 35 degree angle toward the engine.
Although not the same as the 'factory' 968T, and may not be as efficient as the 944T intercoolr - it seems to fit well with minimal amount of metal work (I spent probably about 3 hours hour cutting/grinding the holes) that doesn't jeopardize frame rigidity or require reworks of the hood latch assembly.
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Actually, it does fit within the area of the bumper bar and front bumper cover without issue. Apparently some of the Powerhaus 968 units used a similar setup of a FMIC tucked down in this area (or at least Miles car did anyway).
Still just toying with the idea - looks like it would work.
Upside = no severe metal work/hood latch relocation.
Downside = possible cooling issue + limited power capability (by simple math the overall heat transfer surface area is less than that of the stock 951 unit).
Still just toying with the idea - looks like it would work.
Upside = no severe metal work/hood latch relocation.
Downside = possible cooling issue + limited power capability (by simple math the overall heat transfer surface area is less than that of the stock 951 unit).
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Actually, it does fit within the area of the bumper bar and front bumper cover without issue. Apparently some of the Powerhaus 968 units used a similar setup of a FMIC tucked down in this area (or at least Miles car did anyway).
Still just toying with the idea - looks like it would work.
Upside = no severe metal work/hood latch relocation.
Downside = possible cooling issue + limited power capability (by simple math the overall heat transfer surface area is less than that of the stock 951 unit).
Still just toying with the idea - looks like it would work.
Upside = no severe metal work/hood latch relocation.
Downside = possible cooling issue + limited power capability (by simple math the overall heat transfer surface area is less than that of the stock 951 unit).
Don't really know, other than the results showing this/my intercooler allows ambient temps ingested. This does affect the AC not working well in 100+ temps. Otherwise, neat setup using factory fans with a Ron Davis radiator.
The condenser needs MORE air flow at a Hot Stop! More air flow would make it through the fins.
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As a side note - anyone else note the different orientation of the intercooler tubes (circular flow vs cross over flow)?
Collective brain trust thoughts?
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After being inspired by rude944, and further weighing the capabilities of a FMIC, decided to see how difficult is would be to fit the 951 Intercooler.
After about a couple of hours of marking and cutting, the Intercooler fit without issue.
I was skeptical at first that too much metal would have to be removed, in retrospect - I don't think the structure is weakened significantly. If I decide to, there is enough material left to add a couple of interior braces without too much effort.
After about a couple of hours of marking and cutting, the Intercooler fit without issue.
I was skeptical at first that too much metal would have to be removed, in retrospect - I don't think the structure is weakened significantly. If I decide to, there is enough material left to add a couple of interior braces without too much effort.
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You will need to move the radiator down an inch and a half with this method. Also remember that this can make ac condenser interference a problem. Both are fairly easily overcome, (but to be fair, I still haven't completed the ac install... I'm having too much fun driving it at 1 bar of boost) with a bit of hardware and just some light fab, as you've now observed.
We're gonna do a run of carbon fiber parts this week... Two sets of the naca ducts and the hood side of the intercooler venting ... Want a set?
We're gonna do a run of carbon fiber parts this week... Two sets of the naca ducts and the hood side of the intercooler venting ... Want a set?
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The bumper I have is merely for modeling purposes. I've cut out the center section for fit-up purposes. This will be done to the bumper on my car as well now that I know 'how' and 'where' to cut.
Is there something special about the intercooler?
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You will need to move the radiator down an inch and a half with this method. Also remember that this can make ac condenser interference a problem. Both are fairly easily overcome, (but to be fair, I still haven't completed the ac install... I'm having too much fun driving it at 1 bar of boost) with a bit of hardware and just some light fab, as you've now observed.
We're gonna do a run of carbon fiber parts this week... Two sets of the naca ducts and the hood side of the intercooler venting ... Want a set?
We're gonna do a run of carbon fiber parts this week... Two sets of the naca ducts and the hood side of the intercooler venting ... Want a set?
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Thanks for sharing your details from before - made it a lot easier for me to get this done.
I read that the lower Rad Mount is flipped over to lower the Radiator - can you confirm? What else should be done, anything?
Obligatory teaser pic for model of intercooler duct.
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