How'd you Intercool your D24T?

[Eli]

*** Please keep this thread uncluttered by keeping discussion to a minimum. I would like this to be a "how to" resource with pics and info only. Thanks, Jason***


Since this is an obvious improvement over stock, and so many people seem interested in this modification, I though I'd start a thread showcasing installs.

I'll start.

The car in question is a '79 245 - D24T+ic. More info can be found Here.

I converted to a D24 N/A intake manifold and N/A valve cover (for oil fill location) Then used an eBay 3" intercooler, eBay 2.5" intercooler piping kit, custom fabbed mounting brackets, Silicone 90 degree bending reducers on intake and turbo outlet, cut down intake hoses from a F150 (for bending reducers) on intercooler. I ran out of pre-bent pieces and had to have the bend under the battery pan done. It is not mandrel, so it will be replaced at some point.









I think it turned out pretty nice.




How did you do yours??

[Slobodan]

I started off my Intercooler setup with the Gas Audi 5000 Turbo Intercooler, It was allright better than None. I didn't like it or the piping. So I next tried the 240 Turbo intercooler flipped it up side down, and used alot of piping. results slightly lower boost. more boost drop, slightly cooler enging temps. then I tried out the SAAB 9000 Turbo intercooler I saw a better design in the core and end tanks. noticed a bit of performance increase with that..... Then I decided that I was wanting to clean up my setup. Lets just do it right?

I saved up some money, and bought an Ebay same side IC 2.5 in and outs. 3.5 core thickness with a 6x18 lxw.. Mounted it, and reinstalled the stock turbo. WOW huge difference. much more torque with virtually zero pressure drop from this IC.









And For piping, Its pretty simple. Allthough, I would like to get all 2.5 inch pipings. Hot side is two SAAB 900 IC pipes mated together, then another SAAB pipe with a transition coupler to IC.

Cold side misc 850 turbo piping with a 90 coupler and then I transitions to the N/A manifold.

[Jason]

Here are some teaser pics of the parts I have been collecting. Once my NA manifold is here, I'm going to do it up, assuming its not 12 degrees like it is right now. Its all 3" tubing, and the intercooler is a delta fin 25"x7"x3" Should be a pretty nice setup!

[Jason]

Here it is! My intercooler setup. The cooler is 25x7x3, with 3" inlets and outlets. The tubing is all 3". Yes its bigger than it needs to be, but the NA manifold is a 3" inlet so I figured it might as well all match, and it loooks cool.

If you look closely at the air dam, I cut out the three air intake areas to the full size that is sort of stamped into them. Before there was extra plastic flashing at the bottom and top that made the area about half as big as it could be. It should alow more air flow and most importantly, you can see more of the intercooler! Comming up through by the battery was easy, I cut the thin sheet metal panel behind the headlight just ahead of the battery, and cut into the flat area of the engine compartment that attaches to that just a little bit. There was plenty of space to get the 3" tube up through there. To take the pipe across the front of the engine, I notched out about a 1" deep area of the fan shroud so the tube could fit down in the gap between the engine and radiator. I'm pretty happy with the results, it came out pretty clean!

[Jason]

Thanks! Cant wait to install and and really feel the potential of the setup... Its still necked down to 2" at the manifold.

I also forgot to mention the charge pipe to the intercooler. It doesn't show in that pic, but I reclocked the turbo 180 degrees out from where it was, so the outlet was pointing towards the ground (slightly at an angle really). Anway I came off it with a 90 and then forward up to another 90 to the intercooler. Keeps the engine compartment clean and less tubing around the turbo now that its running under the car. This will also leave more room for the compound setup.

The results? Boost is the same, it spools maybe slightly slower on the way up to 10lbs but not much at all. I do get a little turbo bark now when i let off if its making at least 15lbs off boost. Not too good for the turbo but it sounds cool! Also the pull once the turbo spools up is awesome! The butt dyno confirms there is a pretty big difference. I'm pretty sure its not wishfull thinking, it really pulls stronger!

Jason

[Eli]

Awesome work Jason, very clean install.