sick Rey, everything about your car is just sick

REALLY hoping to meet you / see it next week... know you said you had to work, buuuuuut... finagle dude FINAGLE!!! 8-)

Thank you guys...I have Saturday off and have already confirmed with Amy...see you at Monticello...:D

Thanks Jim. I haven't sorted through my parts bin yet for the frequency valve...I have not forgotten..just a little time crunchy lately...SmileWavy

I pick up my car Friday.......hopefully!

Good to hear Chris, i hope everything is done right and ready to go.

If so, are you going to drive or sell it?...if voting...I say drive that beauty..:D

Impressive...most impressive that you got 'er done considering how much you had to do. I really thought you'd owe K a beirz.

Quite a string of bad luck on this intercooler install. Very bad luck, actually and threatening my TurboPalooza. I need to document it here for my own sanity and character building.
I bought a longneck intercooler from Turbokraft that did not fit correctly and had to send it back. Chris test-fit it on another stock car he had at the shop and agreed with me, and determined that their jig had shifted somehow. They built a new IC and sent it out within a week of getting it, so very good customer service there. But it ate up three weeks time that I now wish I had. https://lh5.googleusercontent.com/-7...6_15_21_12.jpg
When removing the stock shroud, I moved an AC line out of the way and that was enough to crack the brazed joint on the rear decklid condenser. A new one is $500 plus vac and recharge fees. https://lh5.googleusercontent.com/-8...8_13_17_23.jpg
The TK intercooler hits the stock air cleaner housing significantly. Chris had informed me of this and said they did not wish to compromise airflow by offsetting the throttle body neck. Most guys go with the K&N clamped on top of the fuel meter. I didn’t want to do that so I drove down to Rey’s (Speedn1Me) house in NJ, checked out his awesome car, and bought a Ruf air cleaner that he had listed in the classified. The Ruf mailbox has been modified with a notch to fit the larger Rug intercooler. I figured it would be enough. IT WASN’T. And why BFH on a nice Ruf piece so I didn't. https://lh5.googleusercontent.com/-u...7_15_23_12.jpg
## Instead of bashing the Ruf air cleaner, today I decided to modify my own air cleaner by cutting out a notch myself. https://lh6.googleusercontent.com/-e...7_18_20_59.jpg
I drove around and go some sheetmetal, some dremel and jig saw blades, made the cut, formed the patch piece… and learned my TIG argon gas had leaked out. After hours, of course. I have to take the kids to a tournament tomorrow AM and cannot, simply cannot, get to the welding supply in the AM.
## In never say die mode, I drove to a friend’s house who has a TIG welder and got there a little after 10PM, but basically got thrown out of his house by his wife and had to leave it. While I was backing out of his ridiculous 1/10th of mile driveway on a moonless night, I hit his neighbors mailbox across the narrow street and dented/scarred the tailgate on my otherwise pristine black RAM 1500. Probably a $500 respray.

But it get’s even better. Inspired by Paul and Kozmo’s tales of 2:30AM marathons, I got home from that and decided I should at least get the IC all trial-fitted up. I had to loosen the coil bracket that also houses the two threaded holes for the two IC mount bolts, and my stupidly gloved hand manages to fumble the washer RIGHT DOWN THE TURBO UP-PIPE that I had removed the rag from moments ago to install the IC. My magnet won’t make the turn, and now I guess I have to take the turbo off. When I can see and think straight again, I may see if I can removed the rubber coupling from cold side of turbo-to-up-pipe and see if I can get it that way. If not, the turbo has to come out and at a minimum I’ll need gaskets that I don’t have, to say nothing of the time I don’t have. I’m not home for most of the weekend and work will be insane next week right up to my day off (Friday) when I plan to join up with the boys at Turbopalooza.

If the curse would be lifted, I can drop the bumper and turbo Monday night and overnight gaskets and those copper nuts to my house for Tuesday. Then button it all up on Tues and Weds nights in time for a Thursday night shakedown ahead of Friday’s ride out to PA. But holy crap has this been a bad run. And $$$!!! I guess I was due. I read about this kind of crap on this board but it’s always the other guy; it never happens to me. Well, it just did.

That sure was a sheit storm. Hang in there!

What gaskets do you need, don't know your setup?

Oh fuchmein the goatass dood

!!!

SO sorry to hear all this

WTF!?

esp. the mailbox bit... that BLOWZ - I thought it was in the 930 tho at first, least it wasn't THAT

oy

regardless

on the washer... did you read my tale of last week?

coat hanger / round lifesaver (literally?) magnet... fished that infernal fukkin turbo nut right out of my fuucking header pipe it did! McGuyver rig seen har!:

https://lh5.googleusercontent.com/-h...712_152333.jpg

regarding the filter... why not just run to the store and buy the Mr. Gasket tin bits / K&N roundy filter and run it just to get you on the road, then figure out the trimming on whatever Mailbox later - jah???

regardless

come ON my friend... UCANDOEEET!!!!!!

May the Schwartz Be With You!!!

ps. Yeah. It's usually ME!

!!

!!!

!!!!

!!!!!!!!!!!!!!!!!!!!!!!!!

8-)

hang in there brutha, you'll fish that fukkin washer out w/ a magnet on a coathanger, mount up a roundy filter, skip the a/c line, consider yer Ram dent a redneck character feature, and hoist bierz w/ us on Friday - this... I... KNOW!!!

[QUOTE=gsxrken;8171409]Quite a string of bad luck on this intercooler install. Very bad luck, actually and threatening my TurboPalooza. I need to document it here for my own sanity and character building.
I bought a longneck intercooler from Turbokraft that did not fit correctly and had to send it back. Chris test-fit it on another stock car he had at the shop and agreed with me, and determined that their jig had shifted somehow. They built a new IC and sent it out within a week of getting it, so very good customer service there. But it ate up three weeks time that I now wish I had.

I had the same problem, it looks at the same he has paid me the repair.


http://forums.pelicanparts.com/uploa...1405754693.jpg

http://forums.pelicanparts.com/uploa...1405754705.jpg

http://forums.pelicanparts.com/uploa...1405754714.jpg

http://forums.pelicanparts.com/uploa...1405754725.jpg

http://forums.pelicanparts.com/uploa...1405754737.jpg

http://forums.pelicanparts.com/uploa...1405754751.jpg

http://forums.pelicanparts.com/uploa...1405754766.jpg

You have to cut this pipe for better fitting

http://forums.pelicanparts.com/uploa...1405754828.jpg

http://forums.pelicanparts.com/uploa...1405754841.jpg

http://forums.pelicanparts.com/uploa...1405754853.jpg

Man that blows..I feel for you..so frustrating but I'm sure you will knock it out of the park and get that baby running.

Try one of these from Harbor Freight for the washer/nut Flexible Magnetic Pickup Tool

Give me a call when you get a chance this weekend

Ugh. Well, that explains why I haven't heard back from you on Saturdays track time. If its any consolation, I was down to the wire trying to do an intercooler install before a turbopalooza gathering. I ended up aborting and putting the stock one back on as documented here:

http://forums.pelicanparts.com/911-930-turbo-super-charging-forum/480133-incoming-kokeln-i-c-charge-air-cooler-questions-install.html

For some reason, when people say an intercooler is a "bolt on" mod, often that means it "bolts on" after a whole mess of cutting, welding, and most important...cursing.

Glad the replacement IC got there safe and sound, thanks for giving us the opportunity to make it right for you.

That is one lousy string of luck!

If you don't have one of those flexible aluminum rods with the magnet on the end, get any telescoping magnet and sacrifice it to the installation, appease the turbo gods. Or McGuyver something like Paul, attach a small refrigerator magnet to a string or welding rod, fish that down the compressor outlet and retrieve the hardware.
All way faster & cheaper than a turbocharger R&I.

The A/C condenser can likely be brazed again by a radiator shop. They fix things like this all the time.

Hi Thomas,
Yes, yours and Ken's are the two intercoolers that were "off." Still a mystery. Glad you were able to get that reworked locally and it didn't have to get shipped across the Atlantic twice more. It just made more sense for us to pay for that, much faster for you.
I think the charge pipe needed trimming because the intercooler inlet became slightly taller during refabrication?
The car is driving well now?

Hi Chris

Yes it was the best solution for this problem, thanks for your help!
The inlet was taller after the refrabrication, the trimming was the simplest solution.

Yes the car is running well I am now 700 miles driven.
I'm still waiting for my turbocharger from Brian (Rarly8). The turbo is being rebuilt.

My Conversion / Rebuilding you can find here

http://forums.pelicanparts.com/911-engine-rebuilding-forum/819630-another-930-engine-conversion.html

Hi Chris - there's a third one - mine. I thought it was a self induced install issue, but after seeing these, my issue seems the same. I've been running it this way, but the rear of the IC is a little too high so I've had some minor rubbing with the screen on the deck lid, and as you can see the down pipe hose interferes with the engine lid when opening and closing. Been travelling too much for business so I haven't had a chance to deal with it, but now it looks like I'm in good company and I may not be the cause of my problem!

I'll send you an email and we can figure out the best way to deal with it.

Richard
http://forums.pelicanparts.com/uploa...1405994009.jpg

Made some progress. Air cleaner modded and TIG'd up to clear the intercooler neck. Think I'll spray bomb it for now and get it all powder coated over the winter. Curious to know if anyone reproduces the stickers?

https://lh4.googleusercontent.com/-y...7_22_11_28.jpg

https://lh3.googleusercontent.com/-Y...7_22_11_28.jpg

Richard -- you've been running it like that since May 2013? Dude, shoulda let us know! Let's fix that for you whenever is good for your schedule. Maybe the next time you're out of town for a while and the car is parked?

After the fitment problem on Thomas', and the misalignment of the coil bracket mount on Ken's about a week later, we revised our manufacturing fixtures and verified fitment on an all-stock 1988 930. We'll drop your IC into this fixture, make the necessary adjustments and get it back to you. :-)