Texas Mile/ Intercooler build
10-31-2012, 10:56 AM
#1
Racer
Thread Starter
Texas Mile/ Intercooler build
Inspired by recent intercooler threads I decided to build an intercooler. The challenge was to complete before attending the Texas Mile. It turned into a 3 week project that kicked my ***.
I used 3 997.2 cores to create a full engine bay cooler. In order to do this I used a N/A center section so the throttle body was facing the front of the car this gave me the space needed.
I designed the cooler using solid works and built a to scale foam model to insure fitment.
After some tweaks, I machined all the sections of the tanks from billet. i added a grill looking piece to the inlet and outlet of the cores. This part is designed to remove the dead space between the tubes by adding a tapered grill. The grill also provided strength holding all the cores together. You can see the part in one of the photos. The inlet tank has 6 vanes welded to the inside to help turn the air in to the core.
I'm currently using a cone filter, but plan on building a filter box and the inlet will come up to the fresh air. Almost the stock location. i will also put 3 fans underneath the cooler. Based on data from my stock cooler and fan arrangement this is a huge help fighting off the heat soak.
As far as efficiency of the new cooler, I compared old data logs that had the same ambient temps with pulls up to 140. This cooler run 25 degrees cooler on average. I need to do more testing but running the car up to 190 i picked up 15 degrees over ambient and this was enough to keep motronic from pulling timing.
I have more pics
As far as the Mile, this was my first time and I didn't have a roll bar so my speed was limited to 190. I didn't know how fast I would be. I ran a 165 at the half and a 193 at the mile. I had to lift to try to stay under 190. I got in trouble for going over the limit. Next year I will have a roll bar and I don't see a problem breaking 200.
I used 3 997.2 cores to create a full engine bay cooler. In order to do this I used a N/A center section so the throttle body was facing the front of the car this gave me the space needed.
I designed the cooler using solid works and built a to scale foam model to insure fitment.
After some tweaks, I machined all the sections of the tanks from billet. i added a grill looking piece to the inlet and outlet of the cores. This part is designed to remove the dead space between the tubes by adding a tapered grill. The grill also provided strength holding all the cores together. You can see the part in one of the photos. The inlet tank has 6 vanes welded to the inside to help turn the air in to the core.
I'm currently using a cone filter, but plan on building a filter box and the inlet will come up to the fresh air. Almost the stock location. i will also put 3 fans underneath the cooler. Based on data from my stock cooler and fan arrangement this is a huge help fighting off the heat soak.
As far as efficiency of the new cooler, I compared old data logs that had the same ambient temps with pulls up to 140. This cooler run 25 degrees cooler on average. I need to do more testing but running the car up to 190 i picked up 15 degrees over ambient and this was enough to keep motronic from pulling timing.
I have more pics
As far as the Mile, this was my first time and I didn't have a roll bar so my speed was limited to 190. I didn't know how fast I would be. I ran a 165 at the half and a 193 at the mile. I had to lift to try to stay under 190. I got in trouble for going over the limit. Next year I will have a roll bar and I don't see a problem breaking 200.
Last edited by tacker; 04-15-2014 at 12:15 AM.
10-31-2012, 01:19 PM
#5
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Fantastic...both in your fabrication skills and in hitting 193 in a 993!!! Damn impressive. Do you have a listing of the engine mods you have? or an est on HP that beast makes?
Kudos to you!!! Can't wait to see you break 200!
Chad
Kudos to you!!! Can't wait to see you break 200!
Chad
10-31-2012, 01:57 PM
#6
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Tacker,
Great job,congrats,you should put the S spoiler intakes to good use, directing ram air straight to the turbos,in my set up I'm 8 degrees colder than yours,that may explain it, of course they may be other variables. I myself did 178 at the 1/2 mile, I'm sure you can go way up there,keep the good work! If I can be of help you can PM me anytime.,cheers,Sonny1.
Great job,congrats,you should put the S spoiler intakes to good use, directing ram air straight to the turbos,in my set up I'm 8 degrees colder than yours,that may explain it, of course they may be other variables. I myself did 178 at the 1/2 mile, I'm sure you can go way up there,keep the good work! If I can be of help you can PM me anytime.,cheers,Sonny1.
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10-31-2012, 02:21 PM
#8
Rennlist Member
That is an awesome IC! The quality of your maching and the finish work is very nice. Would you sell the drawings for the end tanks and other bits required to assemble this? Also, how much clearance is there between the IC and the opening on the tail. I see you have an "S" tail. Is the opening the same size on the standard turbo tail? Great job and thanks for sharing.
10-31-2012, 03:09 PM
#10
Racer
Thread Starter
Thanks for feed back,
Chad
Chad, the engine build summary 3.8 mahle,twin plug,evo cams,mechanical rockers,TI hats,hi rev springs,flame ring,welded heads,all arp hardware,pauter rods,gt3 oil pump, shuffle pin,windage relief,oiling mods to crank,larger TB, 18 g turbos, cat delete, muffler delete (for the Mile) Water/meth injection.
200 shouldn't be a problem, the car is full weight, full tank of gas, passenger seat,spare tire,tools and compressor,
The car is Protomotive live tuned,
I'm thinking about changing the gearing to a gt2 gear ratios with some beefier axles. BTW i'm still running 4wd.
Tacker,
Great job,congrats,you should put the S spoiler intakes to good use, directing ram air straight to the turbos,in my set up I'm 8 degrees colder than yours,that may explain it, of course they may be other variables. I myself did 178 at the 1/2 mile, I'm sure you can go way up there,keep the good work! If I can be of help you can PM me anytime.,cheers,Sonny1.
178 in the half is very impressive, I had traction issues, I was trying for 170 but couldn't get there.may be next year.
The car felt very stable at 190. I was surprised.
That is an awesome IC! The quality of your maching and the finish work is very nice. Would you sell the drawings for the end tanks and other bits required to assemble this? Also, how much clearance is there between the IC and the opening on the tail. I see you have an "S" tail. Is the opening the same size on the standard turbo tail? Great job and thanks for sharing.
__________________
Scott
Scott, I would consider selling the intercooler design,but prefer to sell it as a complete kit ready to install. the welding/ machining and NA center section. With instructions. First I need to data log and prove efficiency. I know basal Skull has done allot of testing but he is running 2 cores.
__________________
Fantastic...both in your fabrication skills and in hitting 193 in a 993!!! Damn impressive. Do you have a listing of the engine mods you have? or an est on HP that beast makes?
Kudos to you!!! Can't wait to see you break 200!
Kudos to you!!! Can't wait to see you break 200!
Chad, the engine build summary 3.8 mahle,twin plug,evo cams,mechanical rockers,TI hats,hi rev springs,flame ring,welded heads,all arp hardware,pauter rods,gt3 oil pump, shuffle pin,windage relief,oiling mods to crank,larger TB, 18 g turbos, cat delete, muffler delete (for the Mile) Water/meth injection.
200 shouldn't be a problem, the car is full weight, full tank of gas, passenger seat,spare tire,tools and compressor,
The car is Protomotive live tuned,
I'm thinking about changing the gearing to a gt2 gear ratios with some beefier axles. BTW i'm still running 4wd.
Tacker,
Great job,congrats,you should put the S spoiler intakes to good use, directing ram air straight to the turbos,in my set up I'm 8 degrees colder than yours,that may explain it, of course they may be other variables. I myself did 178 at the 1/2 mile, I'm sure you can go way up there,keep the good work! If I can be of help you can PM me anytime.,cheers,Sonny1.
178 in the half is very impressive, I had traction issues, I was trying for 170 but couldn't get there.may be next year.
The car felt very stable at 190. I was surprised.
That is an awesome IC! The quality of your maching and the finish work is very nice. Would you sell the drawings for the end tanks and other bits required to assemble this? Also, how much clearance is there between the IC and the opening on the tail. I see you have an "S" tail. Is the opening the same size on the standard turbo tail? Great job and thanks for sharing.
__________________
Scott
Scott, I would consider selling the intercooler design,but prefer to sell it as a complete kit ready to install. the welding/ machining and NA center section. With instructions. First I need to data log and prove efficiency. I know basal Skull has done allot of testing but he is running 2 cores.
__________________
10-31-2012, 04:04 PM
#12
Nordschleife Master
Your car must be at a 600+ HP level. Ruf claims that a stock bodied Turbo R has a top speed of 205mph, and several Turbo R owners have seen that demonstrated. The Turbo R is rated at 490HP. While I don't doubt the veracity, I have a bit of trouble making that math work.
Have you made any aero mods to your car? A-pillar fairings? aero mirrors (or no mirrors)? remove the wipers, front and rear? At 200+ MPH, these are quite important.
Have you made any aero mods to your car? A-pillar fairings? aero mirrors (or no mirrors)? remove the wipers, front and rear? At 200+ MPH, these are quite important.
10-31-2012, 04:26 PM
#13
Rennlist Member
Your car must be at a 600+ HP level. Ruf claims that a stock bodied Turbo R has a top speed of 205mph, and several Turbo R owners have seen that demonstrated. The Turbo R is rated at 490HP. While I don't doubt the veracity, I have a bit of trouble making that math work.
Have you made any aero mods to your car? A-pillar fairings? aero mirrors (or no mirrors)? remove the wipers, front and rear? At 200+ MPH, these are quite important.
Have you made any aero mods to your car? A-pillar fairings? aero mirrors (or no mirrors)? remove the wipers, front and rear? At 200+ MPH, these are quite important.
Agreed, the aero bits will help.
10-31-2012, 05:41 PM
#15
Rennlist Member
The extra oomph comes from the car being in Texas. Duh. LOL.
What type of machine are you running those end tanks on? I was just going over an intercooler design yesterday as that is one of the last things on the list. It looks like we can pull this off on a three axis with a flip and indicate? or did you have the fourth axis?
What type of machine are you running those end tanks on? I was just going over an intercooler design yesterday as that is one of the last things on the list. It looks like we can pull this off on a three axis with a flip and indicate? or did you have the fourth axis?