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Intercooler pipes

Diver944

Diver944

Active member
I think I may have stumbled across a really good value way to replace the stock curved black intercooler pipes with some super shiny straight ones of a larger bore.

This week I have been trying to reduce the induction noise a little so that I have no sound problems at the clubs trackday at Donington next week. To do this I bought two 3" silicon elbows (a 90 degree and 45 degree) and a straight connector pipe. The idea is to replace the hard metal curve from the Vitesse MAF pipe with a soft, sound absorbing silicon curve then introduce a 90 degree bend so that my air filter points straight down into the space behind the headlamp. This will hopefully reduce the turbine and dump valve sound just enough so that I have no problems at any UK circuit.



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When I opened the box and was doing a trial fit last night it struck me that with a smaller 2.5" diameter tube and connectors you could replace both of the curvy black intercooler pipes with shiny straight ones and a slightly cut down 45 degree silicon elbow. This will supposedly reduce any lag a little more and also removes that very soft, long restrictive hose that comes straight out of the turbocharger. Parts from PSH hoses in Leicester will be circa £80

There are only two problems to overcome:

1. These shiny pipes have no port to connect the dump valve.

Possible solutions are - dump to atmosphere or a silicon T piece to connect the hard pipe to the throttle and use the Tee to connect in the dump valve

2. There is no banjo bolt to provide an airline to the wastegate

I think a simple solution would be to use one of the blocked off ports on the manifold itself. Can anyone see a problem with this?

Here's a pic of the sort of T piece I need



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Here's my previous aborted attempt to reduce the sound.

I lined the area behind the headlight with Dynamat sound absorbing material and then spent many hours chopping and cutting the Lindsey MAF trap so that the air filter was completely surrounded my Dynamat material. It finally fitted reasonably well, but unfortunately the headlight bracket grated up and down against the air filter so badly that I feared for its long term lifespan so removed it.

So much for custom manufactured MAF traps designed to fit 944s :ROFLMAO:

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Paul

The CEC and BEC Westfields et al have to make a plenum box that shrouds the air inlets to cut down the noise. My VX powered westy had an inlet nearly as loud as the 105db exhaust on full chat [8D]

This is not a sound absorbing thing as they are made of carbon, plastic etc so hard surfaces are not the issue, simply they reduce the sound on the outside.

Probably a silly solution but for a track day cant you tape some plastic/cardboard laminate etc over/around the inlet cone (allowing space for air of course) your standard air inlet will then be the wheel arch hole?
 
I would be cautious using unridged hose connectors on the pressurised side of the induction. I find with Beaky unless the jubilee clip is hard against the back side of the rib hoses will move and pop off.

As far as out let ports there are screw on connectors (like a tyre valve) that you can put through the wall of a silicone tube for the banjo connection. The banjo connection is placed where it is to measure the pressure from the turbo - any further down the line will introduce latency. You can't take it off the inlet manifold as it is interrupted by the throttle body.
 
It's always struck me that with the standard airbox removed there is a substantial amount of space liberated. I've thought about the possiblilty of mounting the intercooler horizontally in this space, creating some ducting to direct the air from the top slot in the PU to the underside of the intercooler and cut some vents/louvres in the bonnet - 996 GT3 style, for the air to vent out once it has passed through the intercooler. It might therefore be possible to mount the air filter behind the badge panel like with an S2 which might give you a plenum chamber effect, especially if you lined the inside of the badge panel with some sound deadening material. I'm not sure how air gets into the space behind the badge panel though.
 
Cheers Guys, all good points [:)]

Paul, The air inlet already is that hole in the wheel arch and I have thought about a plastic cylinder around the filter that is hard against the side of the wing but I think the sound from the turbo will still go straight down the MAF pipe, through the filter and out the hole in the wing. If you take the air filter off the MAF you can currently see straight through to the turbo impellor and sound likes to travel in straight lines.

Hopefully the introduction of two curves made of silicon will bounce the sound around just enough for me to have no problems. Bedford is one of the strictest places in the country with an 87.5db drivebay and I tripped it at exactly 87.5db (with a self imposed 5krpm limit) so I don't really have a serious problem - but I want to be sure.

John, that's a very good point about hoses blowing off non ridged pipes on the pressure side [:eek:] I think I'll abandon that idea for a while and just save up for the $325 www.speeforceracing.com pipes that already have connections for the BOV and wastegate.

Scott - you're just going extremely silly now [:eek:] you know I like to keep my car standard :ROFLMAO::ROFLMAO::ROFLMAO:
 
I think it's a good configuration. I thought about it after seeing an article on the 996GT3RS that has an extra radiator in the front bumber and has a vent just in front of the radiator lip. I'd imagine the intercooler would work alot more efficiently as you don't have a radiator and a dirty great engine behind it. And with the space liberatred by moving the intercooler from it's current location you could plumb in the cone air filter like in an S2. Not sure if this has any benefit for sound deadening but at least it is a more enclosed space thant the area behind the light.

Paul - I don't suppose there is any benefit in positioning the MAF inbetween the intercooler outlet and the throttle body? Maybe you could plumb in the outlet of the recirc valve inbetween the MAF outlet and the throttle body? At least this would take away the sound of the recirc valve.
 
Well I've had partial success.

I managed to fit both silicon elbows so that there is no straight line from the turbo to the airfilter and the filter fitted nicely in a vertical position right at the bottom of the cavity behind the headlamp. Unfortunatley the headlamp bracket scrapes the filter very violently so that I fear for it's long term lifespan. I could have cut out half of the bracket like I have seen some Rennlisters do but instead I've spoken to my local K&N stockist and I'm ordering a slightly narrower filter which according to my measurements will give adequate clearance.

Nearly there [8|]
 
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