996 Turbo / GT2 Turbo discussion on previous model 2000-2005 Porsche 911 Twin Turbo and 911 GT2.

997.2 Intercoolers - Wow!

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Old May 16, 2012 | 02:41 PM
  #331  
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When I visted my German tuner in Europe a few months ago he brought up the point of them blowing apart. Thus I'm sure Ben is not the only one. I know 2 other people with same issues. But at low boost it's a no Brainer for $1000.
Do anyone log for flow or just intake temps.
 
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Old May 16, 2012 | 02:51 PM
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Originally Posted by MARKSKI@911tuning
When I visted my German tuner in Europe a few months ago he brought up the point of them blowing apart. Thus I'm sure Ben is not the only one. I know 2 other people with same issues. But at low boost it's a no Brainer for $1000.
Do anyone log for flow or just intake temps.
A while back we took them to a local company called Wilson Manifolds for flow testing. These were our results. I suspected a long time ago that they'd be great for cooling, but not so much for flow. They actually had worse flow then .1 turbo IC's, but cooling efficiency is much improved because of the new core design.

But like Markski said...for $1000 at low boost...definitely a no brainer.

 
Old May 17, 2012 | 06:46 AM
  #333  
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Question

Originally Posted by bad107
I have changed my mind on these intercoolers. These intercoolers are great until you run a lot of power through them. I had one 997.2 intercooler leak and replaced under warranty. Last week I was driving and the endtank completely blew apart. I was running 110 octane at ~1.7 bar.

I am done with these intercoolers. Wasted time and money if you plan on going with medium to high power. I have tial alpha 28s BTW.

May I ask? If 997.2 intercooler is able to handle the boost pressure produced by K24/20G blower? Tks!
 
Old May 17, 2012 | 09:40 AM
  #334  
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alpha 28 at 1.7 bar
 
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Old May 17, 2012 | 10:16 AM
  #335  
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Originally Posted by bad107
I have changed my mind on these intercoolers. These intercoolers are great until you run a lot of power through them. I had one 997.2 intercooler leak and replaced under warranty. Last week I was driving and the endtank completely blew apart. I was running 110 octane at ~1.7 bar.

I am done with these intercoolers. Wasted time and money if you plan on going with medium to high power. I have tial alpha 28s BTW.
I am trying really, really, really hard not to say I told.......

In any event, props for running the test, Ben.
 
Old May 17, 2012 | 10:17 AM
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Originally Posted by Dr_jitsu
I am trying really, really, really hard not to say I told.......

In any event, props for running the test, Ben.
thought you would be too busy making smoothies to see this
 
Old May 17, 2012 | 10:29 AM
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Originally Posted by earl3
Thanks for the info Ben, through you and others I think we've found the ballpark limits on these things. I'm currently testing an all aluminum 16 row prototype cooler that retails for not much more than the .2s and provides awesome cooling, stay tuned for a writeup on them!
Damn, you are a tease!!!

Anxiously awaiting! New thread or continuing this one?
 
Old May 17, 2012 | 01:02 PM
  #338  
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Originally Posted by bad107
Incorrect...the 997.2 intercoolers were not designed to run that much air through it.

The GT2RS puts out 1.5-6 bar from the factory and uses these intercoolers. However, the turbos do not put out the 48 lb/min that the alpha 28s do.
Boost is simply a measure of restriction though, correct?

So, assuming the same engine, 1.6 bar of max boost pressure at the same rpm would be the same approximate quantity of air, regardless of if it's a pair of VTG's, or 2868's or 3076's. Wouldn't it?

Regardless, I guess the implication is that the downstream endtank of the 997.2 IC's is too restrictive if one wishes to run 1.5+ bar on a 996TT?
 
Old May 17, 2012 | 01:59 PM
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i would expect it is the pressure that is blowing these and not directly the amount of flow. pressure = flow X resistance so more flow or more resistance increases the pressure. bigger turbo should just allow more flow and as a result more pressure sooner. resistance hasn't been changed in this example. JMHO
 
Old May 17, 2012 | 03:33 PM
  #340  
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Originally Posted by pwdrhound
I wanted a much more durable and OEM like fit and achieved this by simply cutting the eight stock metal clamps in half and then riveting a piece of aluminum (1/16"x0.75"x1.75") to the center of the stock clamps in order to accommodate the thicker cores.
pwdrhound- That looks like a nice, neat installation. I also was going to splice my clips, but went the route of using stainless steel ties to make a loop at the bottom half of the IC bracket,through the square bosses, and used the stock clips. Holds great and the clips can easily be unclipped. Got the s/s ties at Home-depot where they sell the telecommunication hardware. I agree that the plastic zip-ties will not last.
 
Old May 17, 2012 | 04:23 PM
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Originally Posted by pumptech
i would expect it is the pressure that is blowing these and not directly the amount of flow. pressure = flow X resistance so more flow or more resistance increases the pressure. bigger turbo should just allow more flow and as a result more pressure sooner. resistance hasn't been changed in this example. JMHO
You are correct sir. Very simple math. If brand X turbo is showing the same boost as brand Y turbo through the same intercooler and piping than the volume of flow must be the same. Boost is a measure of resistance. You can not change one constant without changing the other. You can not flow more air through the same IC and piping and have boost remain unchanged.
 
Old May 17, 2012 | 04:28 PM
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Originally Posted by uschoice
pwdrhound- That looks like a nice, neat installation. I also was going to splice my clips, but went the route of using stainless steel ties to make a loop at the bottom half of the IC bracket,through the square bosses, and used the stock clips. Holds great and the clips can easily be unclipped. Got the s/s ties at Home-depot where they sell the telecommunication hardware. I agree that the plastic zip-ties will not last.
That should work too. I just didn't want anything cutting into the square bosses so I elected to just lengthen the clips so they retain their function as originally designed. Many ways to skin a cat I guess....
 
Old May 17, 2012 | 04:29 PM
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Originally Posted by pwdrhound
You are correct sir. Very simple math. If brand X turbo is showing the same boost as brand Y turbo through the same intercooler and piping than the volume of flow must be the same. Boost is a measure of resistance. You can not change one constant without changing the other. You can not flow more air through the same IC and piping and have boost remain unchanged.
a k16 with 5" intercoolers at 1.5 bar puts out the same air as a gt35 at 1.5 bar?

I understand if the piping is the restriction then it will only flow what the pipe lets it, but the oem piping size of ~2.2" is plenty big for most turbos.
 
Old May 17, 2012 | 04:39 PM
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Originally Posted by bad107
a k16 with 5" intercoolers at 1.5 bar puts out the same air as a gt35 at 1.5 bar?

I understand if the piping is the restriction then it will only flow what the pipe lets it, but the oem piping size of ~2.2" is plenty big for most turbos.
I am looking at this from a purely physics stand point. Maybe there is something else at play so if someone can explain how you can flow more air through the same pathway (IC+piping) and have the pressure remain unchanged than I'm all ears... I'm not arguing by any means, just curious what I'm missing.....
 
Old May 17, 2012 | 04:52 PM
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Originally Posted by pwdrhound
I am looking at this from a purely physics stand point. Maybe there is something else at play so if someone can explain how you can flow more air through the same pathway (IC+piping) and have the pressure remain unchanged than I'm all ears... I'm not arguing by any means, just curious what I'm missing.....
You have to look at the whole system, not just the IC piping as the point of restriction. At some point, the flow is restricted elsewhere like the turbos or exhaust. That said, pressure is pressure and at some point the plastic end tanks will pop off or even leak before then. To get an accurate determination, one would have to pressure test the ICs and determine at what PSI they start leaking or pop off.
 


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