Secondary Cooling System......Done!.....AGAIN

[948]

BETA SYSTEM HAS NOW BEEN INSTALLED, TO REPLACE THE ALPHA SYSTEM, SEE BOTTOM OF THIS PAGE FOR THE UPDATE

........HaaaHaaah.
It's in and ready to go. This set-up should give me the added cooling capacity, though my enigne temps were not out of control. They would slowly creep up to 210-218 with 90 degree air temp A/C core in place, after a 5-10 min hard run.

I made some custom aluminium wye's to tap into the exsisting system. The core is a perma-cool 305 unit for fluid cooling.
The fan is a SPAL 5.2 inch 313 CFM unit.

[944-LT1]

Oh crap

Sorry Paul.... Im an idiot. I forgot to send that damn pump.

I will make sure to send it out tomorrow if you still want it. I apologize. School started and I kinda lost my mind and forgot about it until I saw this post.

[944-LT1]

BTW, Looks great....looks like you could have mounted 2 of those fans on that cooler. Or, 2 of those coolers in that area.

How is that fan controlled? Is it variable or just go?

[948]

BTW, Looks great....looks like you could have mounted 2 of those fans on that cooler. Or, 2 of those coolers in that area.

How is that fan controlled? Is it variable or just go?

Don't worry about the pump, your diagram was enough to help me figure out the rest.

I could mount 2 fans, that is why the current fan is on one side not in the middle. I want to see if 1 will do the trick in stop and go. I must say that the amount of air this fan moves is very impresive, for it's size.
I am running it thru a relay that is triggered by the main fan system....you can see the relay mounted on the rad support.

That is the biggest cooler I could fit in that area, 5.75H x 3.00W x 14.00L.
The open space to the right is where my intake filter lives.

The original duct is sectioned off, internally, to force the air thru the cooler.
I may add a duct behind the cooler, if the hot air starts affecting intake temperatures.

[944SS]

Nice job with the Tig.

[RobotMachines]

Looks good Paul! I agree, nice welding

[948]

Nice job with the Tig.

Although my aluminium TIG welding is good......it's not that consistent. I did not trust myself on these tubes, thin walled aluminium is not easy to weld.
All the credit goes to our welder Ken. He started welding 6 years before I was even born.....I think he even does it with his eyes closed

[ghostcloak]

Just outa concern (because I do see alot of you adding more improvements to the cooling system), is Renegade's custom cooling system alone not enough for our cars? (especially if they are running close to 400hp?).

[dawgz83944]

Just outa concern (because I do see alot of you adding more improvements to the cooling system), is Renegade's custom cooling system alone not enough for our cars? (especially if they are running close to 400hp?).

Ask Predator

1 of 2 or both things are a weakness:

1) not enough radiator surface area
2) not enough space between radiator and engine to allow for hot radiator air to flow out quickly enough,

[944-LT1]

is Renegade's custom cooling system alone not enough for our cars?

hahahahahehheehe

If it worked it wouldnt be an "essentially no cut or weld conversion!" Its probably good enough for a V6 though

[turbobob924]

This looks pretty cool however I wonder if that at the temps you were seeing that an Oil cooler would have been aggod idea? How low did you oil pressure drop at the high temps?

[948]

This looks pretty cool however I wonder if that at the temps you were seeing that an Oil cooler would have been aggod idea? How low did you oil pressure drop at the high temps?

I have had the stock 951 oil cooler, plate design 5"x4"x7", installed since day one....7 quarts in the system.

The oil pressure runs as follows;
Cold @ idle = 4.5 bar
Hot @ idle = 3 bar
Hot @ >2500rpm = 4 bar

The oil pressure will get a little higher as all the internal parts break in.

[ShApE]

those welds look awesome.

[948]

Before the new year I finished up my second secondary cooling system...I SHALL CALL IT BETA.....
This system still uses the stock size radiator and now uses the 944 turbo radiator fan's & shroud. The secondary radiator is made up of 2 Ford van E300 rear heat exchangers. Each has a core measurement of 18Wx3Hx2D. When stacked these fit very well in the spot that my intercooler used to call home!

I first removed the vertical radiator side supports. Next, I fabricated new sheet metal supports that were to be installed in a new configuration. The bottom of each support is attached to the cross support, just like stock. The new placement tilts the top of the radiator forward ~7 degrees. This tilt allows the fitment of the stock shroud and fans, even with my electric water pump.
I attached the new supports via welding and SEM body panel adhesive. I also fitted a universal AC core using the stock style isolators. The core is fully sealed to the sides and the OE top plastic seal, as not to affect OE ram-air.
The secondary radiators are plumbed in series with the stock heatercore. I am using an H valve so that water is always flowing, regardless of season.
I have driven with this set-up 10-20 times with great results so far. With the outside temps below 40-50 the engine barely heats up to the 160 T-stat on the highway and goes below while at idle!
Obviously the real test will be during summer with the A/C on.
The stock fans and shroud can't be beat and so I don't expect any problems there.

Here are some pics, the originals can be found in my albums.