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Smile Intercooler air shrouds available

With all these intercooler threads going, now is a good time to let the community know that TurboKraft has intercooler shrouds available.

TurboKraft had a Turbo in for a major rebuild, and we noticed the hole cut in the Garretson/Andial IC shroud was hardly rectangular -- it was more of a trapezoid and didn't match the intercooler core's dimensions at all.

What started off as filling in the edges and re-shaping the opening turned into making an all-new shroud, then a batch of reproduction shrouds. We found the same fiberglass guy who had made them for Garretson and he made 20 more. Same thick high temp material, same black gelcoat finish on top.

We opted to not cut out the center when making them, instead choosing to leave that to the installer so he can make his cuts line up exactly with the intercooler's core.

If you have an Garretson/Andial intercooler missing a shroud, or wish to shroud another non-full-width intercooler, this is what you need.










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Old 05-23-2014, 04:38 PM
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should have made them out of CF lol
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Old 05-23-2014, 05:39 PM
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Nice serpentine AC condensor in there too...
I've had a couple of those Garretson halfbay shrouds and wondered why the opening was cut at an angle that didn't match up with the edge of the intercooler core... like you mentioned.

One is still in the car and the hole is squared off and matched to my Kokeln intercooler core now.
Old 05-23-2014, 06:09 PM
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Cool idea.....cost?
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Old 05-23-2014, 07:05 PM
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Price?
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Old 05-23-2014, 08:25 PM
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Would these fit a Koklen intercooler
Old 05-23-2014, 11:25 PM
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Quick questions: 1. Are you having them made in full bay width for those of us who have deleted our A/C; and 2) would these fit Garretson/Andial IC's?
Old 05-24-2014, 07:08 AM
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Quote:
Originally Posted by oz 930 turbo View Post
Would these fit a Koklen intercooler
I have a Garretson fiberglass shroud and I enlarged the opening to fit a Kokeln intercooler so I'm thinking the one Chris sells probably would too.
This pic is taken before removed the rear wiper.
Old 05-24-2014, 07:42 AM
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Price check please? Count me in for one.
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Old 05-24-2014, 09:08 AM
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I too am gonna need one of these provided the price is reasonable. Doesnt look like its on the site yet.
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Old 05-24-2014, 02:36 PM
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+1 to request a full bay one for all those who have have deleted A/C

Quote:
Originally Posted by zaman fu View Post
Quick questions: 1. Are you having them made in full bay width for those of us who have deleted our A/C; and 2) would these fit Garretson/Andial IC's?
Old 05-25-2014, 10:46 AM
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Hi,

These are $138/ea.

That's considerably less than the $220 + S&H we paid Andial when we needed one for a build years ago.

Looking into rubber shroud seals to go atop the old intercoolers, too.
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Old 05-25-2014, 08:49 PM
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Ken -- we though about carbon fiber, but that can be really difficult for the DIYer to cut on his own and end up with crisp, clean lines. I'm sure those with professional bodyshop experience can chime in with better tips, but this cuts well when you apply painter's tape and cut through the tape with a cutoff wheel. No muss, no fuss.
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Old 05-25-2014, 08:50 PM
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Full width -- okay, we'll look into it.

But consider that if your intercooler is really big (like TurboKraft's full-width billet intercoolers) and obstructs most of the wings' louvered opening, you might need to shroud it completely. We have a theory that it isn't always necessary to completely duct all air through the intercooler.

Why?

The factory didn't completely shroud the intercooler on the 1991-94 Turbos.


(photo credit: spennyb's build thread http://forums.pelicanparts.com/911-engine-rebuilding-forum/626572-964-efi-conversion-using-mbe.html)

Those 6 oval openings to the right of the intercooler feed fresh air right into the engine compartment, completely bypassing the intercooler. Why did they do it? Was there an issue with insufficient engine air cooling without the 6 oval openings in the wing?

Again, this is just a working theory, and we did quick tests on a few cars that were inconclusive. Therefore we fully intend to measure the efficacy of fully shrouding a FWIC on a EFI 930 this summer when it's really hot in Phoenix. Engine head temp, IC outlet temp, and manifold pressure are already measured and utilized by the EFI, and the system's additional channels will allow us to datalog ambient air temps, IC inlet temp & pressure, and engine oil temp.

Maybe we're right, maybe we're wrong -- but we'll have data to know one way or the other.
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Old 05-25-2014, 09:18 PM
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When will they be available?
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Old 05-25-2014, 09:24 PM
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Don't you think that the 6 oval openings were there to bring air to the airbox?
To me the purpose of a full bay block off plate would be to cut openings for the airbox (via a "snorkel") and the intercooler to force the air to feed these two needs and nothing else (and close the rest)

Quote:
Originally Posted by TurboKraft View Post
Full width -- okay, we'll look into it.

But consider that if your intercooler is really big (like TurboKraft's full-width billet intercoolers) and obstructs most of the wings' louvered opening, you might need to shroud it completely. We have a theory that it isn't always necessary to completely duct all air through the intercooler.

Why?

The factory didn't completely shroud the intercooler on the 1991-94 Turbos.


(photo credit: spennyb's build thread http://forums.pelicanparts.com/911-engine-rebuilding-forum/626572-964-efi-conversion-using-mbe.html)

Those 6 oval openings to the right of the intercooler feed fresh air right into the engine compartment, completely bypassing the intercooler. Why did they do it? Was there an issue with insufficient engine air cooling without the 6 oval openings in the wing?

Again, this is just a working theory, and we did quick tests on a few cars that were inconclusive. Therefore we fully intend to measure the efficacy of fully shrouding a FWIC on a EFI 930 this summer when it's really hot in Phoenix. Engine head temp, IC outlet temp, and manifold pressure are already measured and utilized by the EFI, and the system's additional channels will allow us to datalog ambient air temps, IC inlet temp & pressure, and engine oil temp.

Maybe we're right, maybe we're wrong -- but we'll have data to know one way or the other.
Old 05-26-2014, 01:59 AM
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I've built and tested many shrouds and found there is benefit to letting air flow in at strategic locations. You need air for the fan and for the intake. If you can isolate the intake that is perfect. The fan is more tricky. It needs to pull through the intercooler without being restricted to the point that negative pressure under the deck lid pulls hot air through the engine tin holes and rear bulkhead.
In this picture I started with a solid shroud that blocked everything but the intercooler and then added holes for the fan until the temperature in the engine bay fell to near ambient while driving down the road. The intake was fed by the right GT2 duct (not shown). At 7000rpm the fan pulls so hard that I am sure air pulls from everywhere, but the engine bay didn't heat up due to adequate air flow from the shroud.





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Old 05-26-2014, 08:40 AM
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Quote:
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When will they be available?

Available now. :-)
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Old 05-26-2014, 11:31 AM
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Quote:
Originally Posted by 1100sport View Post
Don't you think that the 6 oval openings were there to bring air to the airbox?
To me the purpose of a full bay block off plate would be to cut openings for the airbox (via a "snorkel") and the intercooler to force the air to feed these two needs and nothing else (and close the rest)
That's what I will do in the end...
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Old 05-26-2014, 12:44 PM
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Quote:
Originally Posted by 1100sport View Post
Don't you think that the 6 oval openings were there to bring air to the airbox?
To me the purpose of a full bay block off plate would be to cut openings for the airbox (via a "snorkel") and the intercooler to force the air to feed these two needs and nothing else (and close the rest)
Certainly, it provides fresh air to the right side of the engine compartment, which is available for the air filter housing's circular opening, and the engine cooling fan.

We'll inquire tomorrow with the fiberglass guy what he needs to make a full-width air shroud.
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Old 05-26-2014, 09:22 PM
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