[flash]

no, it wasn't the project i have been contemplating - no, it isn't something that will ever be available as a kit



jeff bought tony's car - it had the beginnings of a roots system on it - never ran right - jeff dumped a TON of dough into it trying to get it to run right



then he brought it over to my place - i poked around and immediately found a few very obvious things that were just plain dumb - in his desperate outreach to get the car sorted out, he had somebody (who shall remain nameless) tell him he needed and then sell him an intercooler, and they then proceeded to stick it in the worst place they could, right in front of the radiator, but 6 inches away - this caused a pressure issue between the two, and worse only allowed hot post intercooler air to get to the radiator - bottom line, the car thought it was 110 outside when it was only 60



i yanked that thing out of there and figured out a way to stick a 951 intercooler in there, but behind the bumper, and clear of the radiator area



before i started pre intercooler temps were 180 plus and nearly 150 after the intercooler



afterward it is 169 and 106 - not a bad improvement at all



water temp gauge used to read 10 o'clock when you were on it, and 9-9:15 cruising - now reads 9:30 and 8:30 respectively



also, the car now hits max boost, where it was only hitting about 80% before - seems to run harder too



and i'm not done by a long shot - haven't even begun to fix all the other stuff that all those other people did



why am i messing with this? well, besides the sickness that just won't let me leave things alone, if i can get this working, it shines a small (repeat small) light on the possibility of a package down the road



film at 11

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[DaveN]

Damn you Flash, you're worse than George Lucas! <img src="/forum/images/smilies/968/wink.gif" class="smilie" alt="" /> Show us 456, say that's it and come back hard with 123.



I quote "no, it isn't something that will ever be available as a kit"

Then you tell us a nice bedtime story about something only the Gods can have then end with

"it shines a small (repeat small) light on the possibility of a package down the road".



I can only deduce a kit is different than a package, you tease.

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[PorscheDude]

Keep the dream alive.

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[flash]

lol - yeah, this is a roots system - i will NOT be doing that IF i put a package together - but, much of the work would cross over to a centrifugal system, which is the only kind i would do - so, NO this will not be a package i will be working to make available - it would be WAY too expensive - but, it could pave the way for a different system



we'll see - i need to see how well this works first - we are a LONG way from getting anywhere yet, but i wanted to share the excitement from last night - it was very gratifying to see the look on jeff's face, as he has been wrestling with this for 5 years, and after all the other guys working on this, last night was the first time it looked like it might work

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[DiREW0LF]

We need video of special moments like this and wallet sized photos to show the grand kids.



<img src="/forum/images/smilies/968/tongue.gif" class="smilie" alt="" />

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[flash]

i did snap a couple of shots - i'll resize them and put them up this morning

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[flash]

as promised -



before: (notice the dent in the intercooler from the unmounted horns banging around):

   



   







after:

   

   





there will be more pics after i clean up the horrendous plumbing and air filter setup the last guy left him with (dented his hood it was so bad)

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[DiREW0LF]

Almost factory looking. Did you put any brackets in to connect the bottom intercooler mounts to the reinforcement?

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[flash]

lol - almost did that, but not yet - will be doing that when we button it up - this mounting was just for the test - didn't want to go through the effort to fab brackets until we knew it worked, and i was done with any diverter pieces i had to add - simple enough though - it will get a nice one on each side



like i said, a LONG way to go from here, but this was a GREAT start

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[jeffski1]

Ya baby! I am soooo happy with our results. Lower temps AND higher boost at the same time. Fantastic. And I have Flash to thank for it.



At first look, I was doubtful we'd be able to make the 951 intercooler fit. But a little cutting here, a little finessing there, and she fit great. Flash achieved a real stock look I think, and it's infitely more functional to boot.



Now the intercooler is located right behind the center air intake between the fog lights. The openning is a little small, so I will definitely be modding the bumper, widening it like the 968 Turbo S bumper, so it is the same height as the fog light/turn signal openning. That will allow even more air flow to intercooler. I'll see if I can find a picture of the Turbo S bumper to post.



Up next I think Flash has some ideas on improving the flow and looks of the intercooler piping. He says he wants to get rid of the hard pipes, as I don't think he like that look. I don't mind hard pipes, but I have to admit, I never cared for the way they were installed in my car. It never really looked "finished off" to me. I like a clean appearance, and hopefully that is what we can achieve in our next go around.

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[jeffski1]

It's a little blury ('cause she's a movin' soooo fast), but here a picture of a Turbo RS bumper. Notice the wider air intake openning between the fog lights. That's what I am going to shoot for down the road. Bigger openning=more air. Not a big deal right now because the intercooler must getting enough air flow with the stock...ok...slightly modified openning, as our temps were rock solid and narry a hint of detonation.



   

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[flash]

i'm "ok" with hard pipes, in the right installation, but the routing of those really screwed any chance of a clean looking air cleaner install, and worse, any shot at having it pick up cool air



i'm probably going to end up with a combination of hard pipes and couplers, but it will definitely route differently, and we'll get the air box separated from the engine bay, and fed by a cold air source



i'm going to be working hard on getting the intake temps closer to ambient - i'm pretty sure i can get close

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[968gene]

would the Turbo S hood vent be helpful to air flow for the intercooler as its now placed?

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[flash]

nope - the intercooler is below the horizontal barrier up front - we don't want to increase airflow into the engine bay, but rather only improve the flow that is already there, utilize it to its fullest, and further isolate the hot things from the things that don't want to be hot



we also don't want to start cutting unsightly holes in the car

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[PorscheDude]

Nice work Flash!

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[flash]

thanks - we're really excited about how it's going - i'm going to work out the ducting, isolation and draw pipe designs this weekend, and then the plan is to assemble it on monday - that will wrap up correcting the ins and outs and cooling



then it's on to the injectors and mapping

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[968gene]

[quote name='flash' post='66062' date='Jan 23 2009, 07:39 PM']nope - the intercooler is below the horizontal barrier up front - we don't want to increase airflow into the engine bay, but rather only improve the flow that is already there, utilize it to its fullest, and further isolate the hot things from the things that don't want to be hot



we also don't want to start cutting unsightly holes in the car[/quote]





I'm not sure if either apply (increased airflow or unsightly holes).

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[flash]

fugly - way too 80's looking - no scoops, vents, ducts, or hickeys on the hood - nothing but sleek uninterrupted lines for me - the ridges in the car bug me enough - definitely don't need it for the supercharger - there are better ways to exit the air

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[PorscheDude]

I agree. Leave the lines of the car as they are.

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[benspeeder]

Flash - that rocks. Jeffski - you are lucky ya got flash to be your engineer!



Seriously - if you guys ever develop a turbo kit - I'd be real interested in buying it when it's time to leave ITR. With a turbo in the 968 the car could run with any SCCA GT2 class race car.



Any power guesses yet?

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