Turbo Intercooler issue

[JRM1970]

OK, I finally got the car back from the body shop and the everything is back in shape to start the rebuild! But I do have one problem/issue with this. On redoing the front nose, I had a clip done from a car that was a non-turbo. ( I know, but for $100 I could not pass it up). the clip nose cone was welded on, but I drilled it off and put a removable one on, no problem there. Theh body guys really did a great job on this one.
Where the problem is, is that under the nose cone, that whole piece is solid and not hollowed out like a turbo section. There is no way to mount the inter-cooler that I have in that small of a space or to get air to it.
My question is: Is there a smaller inter-cooler that I can get to try to use this space, or is it possible to mount a different or smaller cooler somewhere else in the engine bay to get this working?
This is the only thing that is stopping me at the moment from getting this car back on the road....

[Techno Duck]

Sounds like an early clip was welded on. A non turbo 86+ clip is the same as the turbo. I would personally cut out the entire section and do what is possible to fit the intercooler. There is not much option here and even running a differen front mount will require plumbing under the nose panel. Performance will also suffer from a smaller intercooler. Going to a front mount might not be a bad idea but there is not much place to route the pipes.

Basically you would need to cut out the underside and also cut/bend the hood latch support area to allow room for the IC pipes to run under the nose.

[Rasta Monsta]

This guy got flamed a bit for his work, but got the 951 unit in an old style subframe:

924Board.org :: View topic - THE ULTIMATE 951 INTERCOOLER INSTALL

Here is a super clean front mount:

924Board.org :: View topic - Front Mount Intercooler Install.

[thewerxracing]

JRM, there are two good links there.

The best part about working on a turbo car is getting to be creative with the I/C ducting.

This little challenge gives you a great reason to think outside the box.

[JRM1970]

Techno Duck:
I believe that the clip was from an 84/85 model. I knew going into it that is was going to give me some issues, but for $100 for the clip and to get it welded on and straight for another $200 I could not pass it up. Porsche body parts are a rare commodity around me so I snatched this one up. The first link that Rasta put up is almost mirror image to what I have to work with and how the nose cone looks to mine. I do feel a little better that it is possible to cut that out and still have integrity left when done, and the instructions to do it gives an amature wrench wrecker a little confidence that it can be done.

Rasta:
Thanks for the links. That is what I was hoping to see, and a nice write up on it as well. Might be an old post, but he'll not get any flamers from me on it.

Thanks everyone..

[JRM1970]

OK, I have the basic outline cut for the intercooler. Went much easier than I thought. Highly recommend a rotozip and a dry diamond blade if anyone else needs to do this.
Everything is cut with the exception of the top brace. According to the picture below, I need to cut in to the brace to relieve a spot for the connections pipes (right where it says don not cut through).
What I want to know is would it be better to cut from the bottom of the brace and run the pipes under it, or should I go ahead and cut as indicated? Just seems like it would weaken it too much to cut the top.
Also, Do I need to angle the cooler down as much as possible? I assume that the air is forced in from the front bumper and that I will not need to cut anything in the nose cone?

Any thoughts???

[Techno Duck]

Can you do a straight on shot, front to back? I think i would cut from the bottom, but would like to see for sure.

The IC is angled downwards slightly and is fed by a plastic duct that runs right from the top slot on the bumper.

[JRM1970]

I'll get it tonight and send it in the morning. One other thing that I want to check is the position of the headlight rotation bar. I just thought of that while looking at your pictures. That also makes me think I need to go from the bottom as well then reinformce from the bottom and not the top. That way I am not anywhere near that rod or as far away from it as possible.

Thanks Duck..

[Porsche-O-Phile]

Yes the 944 n/a and 951 front ends are not the same. The headers are also slightly different because the 951's slopes down at a slightly greater angle to accommodate the intercooler.

One reason you can't transplant a 931 vented header panel onto a 951.

You could always go with a front-mounted i/c - a lot more efficient too. The delta-T numbers you'll get with a front-mounted setup are vastly better than anything you'd get from a 951 - even with one of those "scoop" things in the header. There's just not much surface area up there.

[Rasta Monsta]

. . .but the nose mount IC delta can be improved greatly by exhausting IC air flow through a vent in the low pressure area in the front of the hood (proven by Steve Bassington, bass_gt at 924board.org).

[JRM1970]

OK, Here is what I have. It is a little more metal on the bottom than what I was thinking, but I still wonder if I should cut from top or bottom...

[Rasta Monsta]

Here is another nice example of improving flow through the nose-mounted IC:

[JRM1970]

OK, after three cuts and two cunks of skin to the hands missing, I finally got the intercooler in!!!
A lot tighter fit in the front than what I was expecting, but it did go it. I still have a stiffening brace to go in, and the bolt down the bottom bracket, but it is done!
One hurdle down, more to come I'm sure..



Tis side for some reason gave me the hardest time. It would not lay down close to the bracket even though there was nothing holding it up.





With nose cone in place. Fits with plenty of room still left.