Modified intercooler

[aerodyn930]

Good Evening, I have decided to join your forum, after lurking for a couple of weeks I could not resist!

Anyway we run a aircraft repair station and a Porsche repair shop, because of the limited choices available for upgraded intercoolers we decided to cut apart a stock L&R unit and re-assembled it using the cores we use when fabricating intercooolers for turbocharged reciprocating aircraft engines. These cores are almost identical to the Secan units famous in europe, the Internal fin count and layout are some of the differences when compared to the cores commonly used by most aftermarket suppliers. to allow reworking of the end tanks a staggered core layout was selected, internal flow vane and radiuses were also installed'. The unit shows no change in external dimensions other than 12mm additional height. We built a accurate fixture and other than needing a different top seal the unit bolted on perfectly. Will begin testing tomorrow, will gather in/out air temps in conjunction with acceleration runs will keep you guys posted,

Would love to compare notes with any of you that have tried this.

Regards, Lou
AERO DYNAMICS

[slow&rusty]

Aircraft and Porsche repair...wow...that is neat and unique.

Neat intercooler can you reference it to a stock intercooler in terms of size, do you have a picture of a stock intercooler side by side with this modified unit?

Yasin

[aerodyn930]

I will check the data on these cores but from doing simple measurements it appears that we have increased the external radiating area by 1.8

Lou

[911st]

Here is some benchmark info: intercooler

Not sure if it will help.

[pkracer21j]

those cores remind me of the one on my old mans p210...I loved wrenching on that plane with him when I was a kid. looks like a nice piece, I'm interested to see the numbers on it.

[matty74]

so you work on porsche aircraft?

[aerodyn930]

Hello there, Yes we maintained two aircraft with the PFM 3200, That concept was way ahead of its time, Anyway Porsche surrendered the type certificate and bought the engines back from the owners, No more Porsche Flugmotor.

Lou

[aerodyn930]

Well on the Intercooler project, This morning we pressure tested the assembly, Welded two angles so that we could mount the original seal frame, Painted the unit and installed a different bulb seal, it is a perfect fit on the factory plastic baffle under the whale tail. Test drove the car and definitely a improvement over the stock L&R unit, On test runs in third gear it was especially noticeable above 4500 rpm's . The customer will pick up the car tomorrow but will drop it off in a week, by then we will have some instruments ready for data gathering.

Lou

[Sick 930]

Hey Lou,

I started reading this thread and right away notice that it was you.
IC looks great. BTW I received my Haltech ecu cable and am ready to get tuned.
I'll give you a call sometime Monday.

regards,
Paul

[JBL930]

Would be awesome if you could do a run logging post intercooler temps with that, then do one straight after with a stock cooler. I would think this will be way better, but would like to know by how much. It would need to be a WOT run, even if it was only flat out in 2nd and 3rd gear

[William930t]

Welcome Lou V. glad you joined the forum! Interesting intercooler project, looking forward to the I/O temp tests. We spoke several times in the PCA paddock at this years Rolex 24. You have quite a working knowledge of 930s and their service needs, I was impressed.

When you get the chance, start another thread about your oil filter cartridge and your fix for the engine rubber seal over the muffler.

[aerodyn930]

Hello Paul, Jonathan and William our plan is to measure in and out temps, plus pressure, 3/8 -24 weld bungs will be installed and Davtron shrouded air temp sensors will be used, The plan is to compare (back to back) the following: stock L&R , My modified unit, Andial long neck and a C-2 turbo unit. The testing will be done in my car (1986 930, Mods K-27 7006, BMC air filter, External recirc. valve,CIS system modified to run open loop, and Fabspeed muffler.) The test will be ( 3 ) third gear pulls from 3K. to redline. The instrument used to display the temps is a JPI edm 700, This will allow us to download a graphical depiction of the recorded data. Will also time the runs as accurately as we can. To test the C-2 Turbo unit we are temporarily removing the A/C cond. off the eng. lid.

William thanks for the kind words, will start those threads tonight,

Regards , Lou

[JBL930]

Some proper testing!! Fantastic! Looking forward to the results!

[spence88mph]

Originally Posted by JBL930

Some proper testing!! Fantastic! Looking forward to the results!

+5, great stuff!!

[aerodyn930]

I was not aware of the several p.m.'s sent to us on the I/C testing , thanx for the interest, testing is complete ,will post results tomorrow night.

Regards, Lou
AERO DYNAMICS

[Reaper930]

Very nice! Looking forward to seeing the details on the runs.

[elvision930]

Wow it looks cool. I like how it retains the same outer dimensions. If and when you decide to produce more. Put me down for one.

[aerodyn930]

Data from I/C test :

Test car: 1986 930, k-27-2006 turbo, Fabspeed muffler, BMC air filter, Modified CIS, (.9 bar boost)

Test conditions: 64 degrees F. , Sea level, oil temp 190 degrees.

Procedure: As soon as 190 oil temp was achieved, two third gear pulls from 3K to 6K

Results: Stock (L&R) Temp in 226 F , temp out 172 F
Modified stock Temp in 221 F , temp out 138 F
Andial (Garretson) Temp in 224 F , temp out 131F
965 stock L&R Temp in 218 F , temp out 137F
On the runs the modified I/C feels very similar to the andial exept that it pulls stronger above 5K
The 965 unit however gives the best acceleration by a small margin,
The test has confirmed our theory about the aerospace I/C cores, they offer a good balance between thermal efficiency and pressure drop .For those looking to retain the A/C condenser this unit may be a viable alternative.

We have begun building a second one for one of our customers.

Regards , Lou

[911st]

Wow, excellent work.

Wish we could get some pressure drop data near HP peak on the different IC's?

Would be best if tested at at the turbo discharge and intake manifold as the connecting plumbing and end tank design can make an effect as much as the core size and design.

[JBL930]

Can't believe i missed this, great result for your unit. If you could make it full bay size i bet it would be even better! Great figures for it's size though, and miles better than stock