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Intercooler Modification

In this instance you are also changing the shape of the tank. The shape will give better gas flow but less pressure build up. Remember an intercooler with 0 pressure drop would be ideal from a performance perspective although unlikely to exchange much heat.

Once the shape is good for gas flow there would be little benefit for increasing volume without increasing the cross section of the intercooler.
 
For what it's worth I gathered from recent talks with a couple of German guys connected with retired Porsche engineers that the IC was one of the most engineered component on the 944 turbo and that it was good for figures up to 400 PS - I must say I took this with a large pinch of salt as I don't quite understand how the characteristics of the IC can be directly related to the output of the engine it's coupled to!

Tom, if the section of the core of the IC doesn't vary, why would a bigger end tank make for less pressure build? I believe pressure will be built slightly more slowly, but the peak pressure figure should remain the same?
 
Remember that gas flow and pressure are essentially equivalent things, they are both the result of the kinetic energy of the molecules in a gas. The difference is direction, flow is about gas molecules with motion in similar directions and pressure is in random directions. In a gas flow scenario such as an engines intake, where the mass flow is a constant throught the intake, you are essentially continually varying wether the gas has pressure or flow. Pre turbo the gas has high flow and low pressure, post turbo low flow and high pressure. Pressure will create flow but it is not as efficient as using flow itself. If you want gas to go in a certain direction such as through an intercooler, you can use a very high pressure and let the molecules move through at random. Or you can use low pressure but direct flow through the intercooler. Shooting the air molecules straight down the intercooler is more efficient as you are forcing the air molecules to go in the right direction to get through the inercooler rather than using pressure and letting them randomly find their way through. Pressure is wastefull as gas molecules spend their time bouncing off each other and walls etc and not going where you want them.
I think the scenario with the 944's intercooler is interesting. I think that Porsche are simply making the turbo work hard and create a big pressure differential across the intercooler as the cars power output is such that it is not taxing the turbo at standard boost pressure. This is not a problem on standard car as turbo boost comes from waste exhaust gas and is free. Using pressure to drive flow across the intercooler has the added advantage that it will use the whole cross section of the intercooler equally. If you start using high flow to get air through the intercooler you can start under using certain sections of the inercooler if the flow isnt balanced across the entire cross section. This makes the intercooler perform worse. I think this is the reason that the standard turbo starts struggling at high rpm and boost as getting pressure high enough to get the flow across the intercooler becomes too much for the turbo. The common solution here would be to move to a bigger turbo which can cope with the high pressure.
I now think that the danger in modifying the 944's intercooler is that you would end up with an intercooler with poorly balanced flow across the intercooler cross section which would negate the benefits of the modification in the first place. The difficulty in getting a balanced flow across the intercooler is probably why Porsche never did it in the first place and might make such a modification far too difficult. I now think simply changing the shape of the end tank wouldn't be good enough and a more complex design would be required. Maybe internal fins in the end tank to direct flow more evenly across the intercooler vains.
 
Hmm... I think I now get it, thanks.[:)]

So increasing the volume of the end tank would not work with an original turbo as it won't be able to flow as much as possible in order to avoid air molecules lose direction by bouncing off the end tank wall.
However, at a given boost pressure, a turbo that will be able to flow more air than an original turbo should then be able to keep the air going into the right direction in a bigger innner end tank?
 
I dont think that the volume of the end tank is a major factor. It does change but I dont think it is the cause of any major change in intercooler performance.
 
We did it for 4 951's about six years ago. Not any remarkable difference over original. It's easy task to do; cost us about 40€/each when a local aluminium welder did it for us. No sense to buy this kind of stuff from USA/Lindsey racing, i suppose your picture is from their website.

I am going to Water/Air type of cooler built inside the plenum.Already have all necessary hardware, bought a cooler from China.Total cost was 100€ [;)] A friend of mine will made me a new flange and the runners from CNC:ed billet aluminium, like the rest of the plenum. He already made me some parts for additinal space, i need to get rid of the air oil separator (oil filler can). I also bought a 964 RS hydrobooster with master cylinder for additional space. Here's one of the AOS relocation parts:

9xx-parts944oilbreatherparts1.jpg


My cooler/plenum will look a little bit like this:

BMWversio.jpg
 
That's the way to go. Heat transfers 25 time quicker in water than in air. The Lotus boys used chargecoolers in their 2.2ltr turbo engines in the Esprit all those years ago. The result was an engine that had a bhp/litre figure that most modern day sportscars still can't match. Shame they didn't have the reliability to go with it.
 
i am not using any part of the OEM intake. It will be built from a scratch. Cooler i am using is so called universal one, which is readily available from most speed shops. One of the end tanks will be removed and then cooler and plenum will be added together, just like that red cooler/plenum installed to BMW (pic i sent). For additional space also turbo will be located another side of the engine.I am also looking faster spool up with this solution.
 

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