924Board.org

[Rob the plumber]

I know it is not the prettiest, but I think it will work pretty well.
The bends were so tight that I could not use any "off the shelf" bends. I used a section of the piping that I bought with the intercooler, and the rest is 2.25" exhaust tubing. For the bends I combed through the radiator hoses at the local auto parts store. I found two hoses with useful looking bends and the right diameter. The two blue silicone 90's were left over from my last DIY turbo project.
The intercooler sits right above the oil cooler and is pretty open to the wheelwell. hopefully my front tire does not throw a stone into the intercooler and cause a leak.
I cut out a small amount of metal in the wheelwell. I also slightly hammered in the inner fender to get the pipe leaving the turbo to sit nice.
I also had to remove the right side headlight bracket/stop, along with the washer solvent bottle. I might retrofit a "pump and bag" like a lot of old American muscle cars did from the factory.
I eliminiated the overboost switch too. The car would not start without grounding the wire to the switch.

I have a nice BOV I can install, but I don't think I need it. Since it would vent to atmosphere, I am guessing that it might cause the engine to run rich momentarily after it purges already metered air. The factory KKK turbo already has a bypass valve anyway. I have to admit that I do like the audible PSSHHHTTT!! with a BOV, even though it can be kinda ricey.





I have only test driven it for a couple miles, so I do not have any driving impressions yet.

I also need to trim the excess off the hose clamps and clean up my fender trimming too.
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1981 931

[tuurbo]

Looks good Dude! How much was the cooler and piping and materials? Roughly...?

What happens with the headlight now?
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1980 924 turbo, MSD, Meth. Inj, otherwise stock.

[Rob the plumber]

I think I have about $70 into pipe, fittings, clamps, etc... and about $200 on the intercooler and BOV.
The headlight operates like normal with the stop bracket removed.
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1981 931

[macBdog]

Woohoo it lives again! Looks good.
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1979 931 with a 350 chev
1973 911E with EFI

[morghen]

oh crap....photobucket again....i cant see any pictures in this website anymore....do you guys see the pics hosted on Photobucket? Imageshack works fine but photobucket is being banned or something.
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Supercharger and EFI kits
https://www.the924.com

[ideola]

Rob
Looks good...couple of suggestions:

• Put some wire mesh where you cut out the wheel well, should reduce the chances of catching road debris
  
• Make an airbox both to and from the IC, as this will make sure you have proper air flow THROUGH the IC and not around it. Lots of articles on Autospeed on how to measure pressure drops using a Magnahelic gauge, would be good reference material for you to optimize cooling in that particular location.
  
• You definitely do NOT need another BOV. The factory unit is technically a recirculating valve, as opposed to a BOV, which vents the charge back into the intake path so that it is properly monitored by the AFM and therefore avoids bonking the AFR.

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erstwhile owner of just about every 924 variant ever made

[Rob the plumber]

Thanks for the input. I am definitely curious about airflow through the intercooler. Measuring it will be a nice science project. It definitely runs better. The engine feels happier once it warms up.

On a side note, I took a maiden test drive to work yesterday. I rolled into the boost at highway speed. When I shifted from 4th to 5th a loose clamp popped off and the car died on the freeway. I've been down this road and knew exactly what it was. I brought tools with me just in case something like this happened. Unfortunately my hood latch decided to crave lubrication, and I could not get it open by myself. I end up stuck on the side of the road near downtown Detroit waiting for a coworker to give me a hand.
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1981 931

[Rasta Monsta]

Ugh, that gives me PTSD. . .it's happened to me on the track. Take your piping to the radiator shop and have the ends beaded. You can also use a wire wheel to roughen up the clamping area to reduce slide-ability.
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Toofah King Bad

• WeiBe (1987 924S 2.5t) - 931 S3

[Rob the plumber]

I just flared the pipe out slightly. so it won't slip out. I should have learned that trick by now.
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1981 931