Intercooler Asian Upgrade

[930guy]

Thought it best to start a new thread as I have now sorted the dilemma I had with the Hargett Shifter. Many thanks to those who replied.
Ok so on to the intercooler, I had purchased this back in the summer and was waiting for the right time to fit it.
I must admit I was a little dubious when purchasing the intercooler but thought it must be better than the factory unit, and as I planned on replacing the turbo in the near future, I figured it would be a good move. I had looked at some of the alternatives but I couldn't find much here in the in the UK. The only ones I could find needed extra parts which I would have to source and too be honest I was not prepared for that journey. So the one I found looked like it would do the job nicely.
After reading some of the replies to the earlier thread I decided on selling the intercooler, I took some photos and started to pack the thing away and to be honest was feeling a bit low. Later that evening I spoke to a friend and told him that I now planned on selling the intercooler and if he anyone that would be interested I would sell cheap just to be shot of it. After some persuasion from him I have now decided to attempt to fit it and see how it goes. If it goes pear shaped I can always return it back to original setup.

Took the morning off work and decided to do a mock fitting. Everything seems to line up and fit ok, your thoughts...

[JFairman]

Looks like it'll fit and work to me... good luck with it.

[Ronnie's.930]

Looks good to me - I would continue with the install, regardless of necessary mods, if it were mine . . .

[jsveb]

Very nice indeed

[turbo nut]

Attach cardboard with masking tape over the fins to prevend bending them helps keep it nice looking.

[mark houghton]

Looks to me like you got her dicked. From this point on it's a no-brainer. Stay with it, finish it, and you'll have not only a lot of personal satisfaction but a killer intercooler.

[911TT33]

Don't under-estimate the "asian full-bay intercoolers". I ran one for years on my turbo 3.2 running 1.2bar of boost... worked well. Much better than that OEM paper-weight of an IC!

[RarlyL8]

The intercooler itself may work fine, it's all the butchering to get it in there that's a potential problem. Relocating A/C components and cutting up your 930 BOV is not what I would consider a bolt-on, if that in fact is what you thought you were buying.

[Tt surgeon]

I tend to agree with Brian. There is a lot of modifying to make it work, the already mentioned 1/2 bays work pretty well, but looks like you got it teed up pretty well.
GL either way.

[JFairman]

The GSF website say's this intercooler was made for EFI conversions and the rear AC condensor will need to be relocated and some fabrication is needed to fit it to a CIS so no one ever said it's a simple bolt on conversion.

And, if an expensive halfbay intercooler is less than 4" thick it will have lower CFM airflow than the other aftermarket halfbay intercoolers that do have 4" thick Bell louvered fin cores and it won't do much more for cooling the air from the turbo than a stock one.

[Ken911]

so will the rear window wiper motor still fit?

[930guy]

Thanks for your views I think I will crack on with the fit.
I will update as and when. I was thinking would it be possible to fabricate some new pipework that will go from the turbo and into the 965 turbo style turbo inlet pipe and do away with the part in the picture. If that is an option what would be the minimum internal diameter of the new pipe I could use. As there may be an issue squeezing the two pipes that come up from the turbo through the narrow aperture.

[JFairman]

I've seen the Garretson hand fabricated aluminum pipe and cast aluminum Kokeln pipe for that but neither are made anymore.

Some guys have gone to a muffler shop and had a piece of cheap mild steel exhaust pipe that fits in the smaller hose swedged out to fit the 930 or 965 rubber elbow hose at the other end. That will work just as well and cost less. Then paint it black so it doesn't rust and looks good.

You could also weld it onto the end of the steel 930 down pipe and not use a silicone or rubber hose and clamps to connect it there. Doing that you can also weld on a hose fitting or bung for a 25-32mm recirculating blow off valve and then use the origonal 930elbow hose instead of a 965 hose with the 25mm hose fitting on top, if you want.
Lots of ways to do it.

[willtel]

Fabricating tubing isn't easy but I have researched a method called "Lobster back bends" that makes DIY tubing possible at home. All you really need is a section of tubing, a chop saw, and some free time. Once you get the rings cut correctly you can hold them together with tape and take them to a good welder to have them tacked and finished.

This method eats up a lot of time and materials like welding rods and gas but it is cheaper than a mandrel bender and you can make tight compound curves with it. Plus, it also looks really cool.

This software maps out the slices so you can print patterns to tape to the tube.
Lobster Back Bends

How to.
Making Lobster Back Piping - Skylines Australia - Page 3

So sexy.

[JFairman]

You can get a much tighter radius than any mandrel bent tubing with multiple cuts and welds like that and it does look cool when a good tig welder fabricator does the welds and lays down the clam shells nice.

Another way to get really tight bends in 3" tubing is using parts of aluminum or steel doughnut tubes welded in and you can chop and weld those too if tighter curves in the tubing are needed.

[Kraftday]

Dude, friends wouldn't let you put that crap your Porsche! Porsche engineers used magnesium for many engine parts for **** sake! Find an old Garretson, get a BB or bite the bullet on the $2200 TurboKraft LN! Consider things like all aluminum, smooth radius bends, bead rolled ends, non ricer hose colors, etc. Or make the 965 work! JMO

[930guy]

Just waiting for some couplings to arrive before I connect it all up properly, just wanted to know where do i connect this part? Do I have to fix it to the intercooler?

[JFairman]

Thats the sending unit for the stock boost gauge in the tach. Mount it somewhere it will see boost before the throttle body.
A threaded bung tig welded on to the bottom of the right side end tank where you have a 2x4 holding it up in one of your pictures might be a good place for it.

[930guy]

Ok great, I have a seperate boost gauge, so would this item be obsolete? To be honest the boost guage has never worked anyway .

[Ronnie's.930]

[QUOTE=930guy;6540788]Ok great, I have a seperate boost gauge, so would this item be obsolete? To be honest the boost guage has never worked anyway .

Yes!

Which one doesn't work - the small one in the tach or the one pictured?