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Intercooler Modification

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barks944

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Anyone here had anything like this done to their intercooler?

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The left hand side has been expanded presumably to flow air over the whole intercooler fin array better.
 
These are end tank mods to increase the volume of the IC end tanks. The idea being that at higher boost pressures the end tanks can become a restriction themselves. I don't think they will improve IC efficiency just improve flow through the intake system. Quite a common mod but i've not seen any back to back comparisons.
 
The intake side looks like its designed to provide restriction to me. Its designed backwards as it will force the air to flow at 90 degrees the wrong way to get through the fins by the time it gets to the shallow end. Makes me think more and more that porsche designed a load of intake restriction into the 944's intake. Think im going to have that out and get it modified.
 
Mine has had the end tank modification done, but it's still not enough when running at 18psi. On a Dyno run at 15psi it can do back to back runs all day long without losing any power. At 18psi it can do about 3 runs but then it gets heatsoaked and starts to lose power.
 
How does airflow over the intercooler on a dyno compare to on the road? Maybe additional airflow over the intercooler would help, it doesnt have a very large surface area after all.
 
You're right, on the Dyno it gets nowhere near the same amount of air as it does in real life on the road. Most Dynos have a weedy little 4 foot fan in front of the car and it just doesn't compare to blasting down the (private) road at three figure speeds
 
ORIGINAL: Diver944

Mine has had the end tank modification done, but it's still not enough when running at 18psi. On a Dyno run at 15psi it can do back to back runs all day long without losing any power. At 18psi it can do about 3 runs but then it gets heatsoaked and starts to lose power.
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Off topic, but if I was in your position (and Im reasonably familiar with your engine, although we havent talked about it), Id be looking at water (/ water & something) injection and leaving the intercooler as it was.

Simon
 
If you spend a little time reading-up then Im sure you agree, that its a small chore when compared with the benefits. Btw: Im talking about water charge injection, as opposed to a water over intercooler spray.

Simon
 
A relative of mine has a 600hp cosworth powered lotus sunbeam. He has a water injection system on that, certainly seems to work for him. You would need a beast of an intercooler to get the same results.
 
Without a shadow of a doubt water injection massively improves the efficiency of the engine - but not due to cooling of the intake charge but due to the oxygen density of water - the more O2 in your intake charge the more power.
 
I admit I have thought about that and the Vitesse piggyback software does have the facility to control that but I have always wondered what size of tank would be needed so that you're not constantly filling it up. The idea with this engine was to get big numbers without running high levels of boost and whilst it delivers 350bhp/400lbft at only 15psi all day long, I had hoped to be able to run at 18psi and have a reliable GT3 type output

Nick_968 has a very good (and very large) front mounted intercooler on his 968 Turbo and it made a huge difference to his intake temperatures. As well as delivering extra power it increases the safety margin by a healthy amount and does not interfere with the performance of the radiator behind it.

The other alternative is a water to air intercooler. These take up much less space than an air to air intercooler and the cooling effects of water are far superior, but once again you need extra plumbing and possibly an extra radiator too. All things to think about in the future
 
Interesting, I'd not considered this aspect of it. So you would actually inject more fuel to match the oxygen content of the water then. Would you put some kind of oxygenator in the tank like you do for fish!
 
I have had a 944 turbo ic modified before. It was to fit it on my old 924 turbo. Had a fabricator cut off the end tanks and modify the shape along with having the pipes relocated so that I could put it in fron of the rad. I will probably just buy a large front mount when I mod my 944 turbo. Maybe a trust one off a skyline or similar. I looked into water injection on my 924 turbo and it is not that expensive. You can use methanol aswell.
 
I am not sure I understand the physics in favor of increasing the volume of the intake end of the IC.

If you increase section and pressure remains the same, then the speed at which the air enters the IC decreases, right?
 
If you increase section and pressure remains the same, then the speed at which the air enters the IC decreases, right?
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True but the volume or amount of air doesnt change so it stays in the cooling area slightly longer and is therefore cooled more.
 
What do you mean by increasing section? The cross sectional area of the intercooler remains the same. The volume of the end tank will increase but I'm not sure that makes any difference. The reason I was considering it was that I thought the shape of the intake end tank looked like it would be detrimental to air flow rate.
 
As I understand it, increasing the volume of the inner end tank along without modifying both the section where the hard pipe meets the inner end tank and the core section of the IC means the air spends more time in the end tank as its speed is being reduced, but as long as the boost pressure remains "high", the speed of air at the outer end of the IC should be the same as with an original IC - Is this correct?
 
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