DIY gt2rs intercooler retrofit
12-04-2011, 08:16 PM
#1
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DIY gt2rs intercooler retrofit
So there was some threads on the 7 GT2/3 forum about the gt2rs intercoolers being somewhat better, and it’s rated for 620 Porsche hp so thought it would be more than adequate for my car. Had done some calculations using equations found on the internet and thought that the stock intercooler is appropriately sized for stock but small if you have any upgrades. On a hot day my AIT’s go into the 40-50’s on the track and my car only boosts to 0.8bar when it’s that hot (1.2-1.3 when cool UMW stage2).
I don’t know anything about flow/intercooler design but I thought I’d give things a shot. I ordered gt2rs intercoolers from Sonnen Porsche. The cores are deeper and longer. My idea initially was to cut up a FVD intercooler that a friend had given me but looking at the end tanks/welds, I didn’t think I could make it work… and thought I could probably make something better.
I don’t have any welding experience except a stick welder I used on the farm when growing up and the occasional project (ie. Muffler bypasses etc that I’ve posted…). Talking to a local tools shop guy, he told me I should use a tig welder. So I bought one and started practicing. I was warned aluminium is hard to weld – it is difficult. All the comments people make on forums about chunky welds on intercoolers – well, those people I’m convinced haven’t tried to weld aluminium. After a while I learned the surfaces really need to be prep’ed, I can’t weld sideways or upside down. Any corner <90 degrees is hard since you can’t fit the welder head in. Any how, after using ¾ tank of argon on scraps, I took the plunge…
I don’t know anything about flow/intercooler design but I thought I’d give things a shot. I ordered gt2rs intercoolers from Sonnen Porsche. The cores are deeper and longer. My idea initially was to cut up a FVD intercooler that a friend had given me but looking at the end tanks/welds, I didn’t think I could make it work… and thought I could probably make something better.
I don’t have any welding experience except a stick welder I used on the farm when growing up and the occasional project (ie. Muffler bypasses etc that I’ve posted…). Talking to a local tools shop guy, he told me I should use a tig welder. So I bought one and started practicing. I was warned aluminium is hard to weld – it is difficult. All the comments people make on forums about chunky welds on intercoolers – well, those people I’m convinced haven’t tried to weld aluminium. After a while I learned the surfaces really need to be prep’ed, I can’t weld sideways or upside down. Any corner <90 degrees is hard since you can’t fit the welder head in. Any how, after using ¾ tank of argon on scraps, I took the plunge…
12-04-2011, 08:21 PM
#4
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Good on ya to give this a go. That looks like a Diversion 180, which is a very nice and very capable shop (non-production) AC/DC tig welder. I have one out in the shop at work for the guys to play with.
Ian
Ian
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12-04-2011, 08:29 PM
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Took me about 2 weeks of my free time. My wife started to complain I wasn’t helping with the kids etc. etc.
Next up is rerouting my cold air intake – I have a good idea for it. And making a shroud that I think I will attach to the tail (vs attaching it to the intercooler).
I won’t be able to do any data logging until the Spring (will post when able) . Seems to run okay though.
It was another fun project. And now I have a tig welder and some experience welding aluminum so can make more things
Next up is rerouting my cold air intake – I have a good idea for it. And making a shroud that I think I will attach to the tail (vs attaching it to the intercooler).
I won’t be able to do any data logging until the Spring (will post when able) . Seems to run okay though.
It was another fun project. And now I have a tig welder and some experience welding aluminum so can make more things
12-04-2011, 09:35 PM
#11
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Very nice job! From a guy who has TIG welded aluminum, I think you did really well! You fabrications skills are quite clever too - sounds like you had a lot of fun. It will be interesting to see how this intercooler does in comparison to the stock one.
Cheers,
Mike
Cheers,
Mike
12-04-2011, 11:22 PM
#13
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Thanx guys!
Was a little worried about welding different thickness aluminum and blowing holes in the intercooler, but with some shielding of the fins, positioning well so the arc is in a good direction and some luck worked out okay I think (I also think the welder I got is particularly user friendly). I used a lot of filler rod and although not pretty in spots, I only had a couple of pin holes to touch up when I checked using soapy water and pressure testing
12-04-2011, 11:53 PM
#14
Dare I ask what the GT2 RS IC go for. That seems like a serious undertaking, Congrats. The proof is going to be getting side by side dyno runs and IAT# to see if this is a more efficient way of cooling. If nothing else I suppose its a sound way of keeping expensive IC hoses from popping off.
12-05-2011, 01:04 AM
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Outstanding project 
Cosmetics can be misleading, this can be a very efficient setup.
I am sure some professional work and testing on end tanks will yield best results however it will be very interesting in the meantime to do some thorough IAT, boost, timing datalogging sessions under the same conditions (under load). Definitely shrouding properly the IC is a must.
Thanks for sharing!
Cosmetics can be misleading, this can be a very efficient setup. I am sure some professional work and testing on end tanks will yield best results however it will be very interesting in the meantime to do some thorough IAT, boost, timing datalogging sessions under the same conditions (under load). Definitely shrouding properly the IC is a must.
Thanks for sharing!