Any successful repairs/re-core of stock intercoolers?

[moparrob]

I know the stock 930 intercoolers are known as being restrictive in their stock configuration and will limit high HP builds. For my specific application I will be using a stock width intercooler though, so I am not interested in a full width new unit.

I have access to a damaged core stock intercooler, and was wondering if anyone has had a stock intercooler re-cored, perhaps with a more efficient core, that still fits the stock dimensions. Has anyone successfully done this before? If so, who did you use?

Thanks in advance for your input.

[jonesb930]

I think the issue would be that the core thickness would be limited to the stock dimensions. All of the upgraded intercoolers I have seen are thicker or wider than stock. My understanding is that adding thickness certainly helps efficiency, but adding width and height does more, hence the "full bay" intercoolers you see. The amount of effort to change just the core on a stock unit alone would be more than just fabricating up a new one. If you run AC you may be limited in your choices unless you are willing to relocate the rear condenser. There are other options if you are looking for a plug and play intercooler with better efficiency. I see them pop up on here from time to time. Kokeln, Garretson, Andial to name a few. Just be careful you don't get a "Long Neck" style that eliminates the bypass valve unless that's something you are wanting to do. There is a post in the 930 forum from someone looking to ID a few, perhaps they will go up for sale soon.

[RarlyL8]

We have a large capacity stock replacement intercooler that was designed specifically for this purpose. Install time is about 15 minutes. It fits in the OE location and plugs into all the attachments. Includes extra vacuum ports and a large 18M port.

[moparrob]

Bill, thanks for the input. You may be right about the lack of core material available to fit the stock dimensions. That is one of my concerns, along with the amount of effort required to maintain the stock appearance and fitment.

Brian, I really like image of the product you have developed. It appears you have already attempted this process and have created an improved solution. That may ultimately be the direction I go in. The black factory looking finish is very nice also.

[jonesb930]

Brian,
That is a nice looking intercooler.

[Axel84]

how does it compare to the turbokraft longneck halfbay Brian

[TurboKraft]

We've used the RarlyL8 intercooler for a basic 930 with bolt-ons and it worked well. It's a simple upgrade from the small original intercooler that's easy to install, and charge air temps stayed under control with a K27 and 1.05bar wastegate spring.

The Longneck intercooler is for those owners also wanting to delete the whole factory cast boost recirculation valve/plenum, like on the 930-S/SE and 964T. The kit includes all the updated diverter valve parts from the 964T. The result is not only power gains from improved cooling, but also improvements to driveability:
* off-the-line acceleration -- the initial hesitation pulling away from a stop is gone
* quicker boost onset
* the engine maintaining boost better during gear shifts