My mind is blown by your approach for this build. All the other channels are about welding, grinding and traditional fabrication. Your take on this build is refreshing and so advanced. 👌🏻🔥🤯
I really like the puzzle piece concept. It’s high precision and really flexible in design. 👍 If you are combining carbon fibre and aluminum make sure to protect the aluminium against corrosion. Sealing the cutting edges should also help. You might want to think about how much the cooler and the oil inside (weight) will stress the the brackets. Aluminum is not very resistant against fatigue. This construction might see a lot of acceleration coming from the suspension especially on a sports car.
Thank you that is great feedback. The covers I had now are plastic and my plan is to make them out of carbon fiber infused PETG which is a reinforced plastic similar to a plastic bottle. I’ll do a stress analysis to be safe and it’s a good idea to add a few Gs to take a rough ride into account! 👍🏻👍🏻
I’m always running up against the episodes becoming too long and some of it does not make it. For the cooler sizing what I did was to use the tables provided by Setrab and try to make a relative comparison with the cooler I had. In the end I had to assume thing such as the flow through speed and an average rpm at which the oil is being pumped around. What I found in the end is that the new coolers require a bit higher pressure difference on the air side but would otherwise give the same or better. In the end I will have to test it and if I find I need more I will go to the Setrab STD 634. I’ve also had a discussion with the people at Setrab to make sense of some of my logic. Please feel free to ask any questions as I’m happy to share or email me if that’s easier.
Wow wow wow, this whole build is so impressive and inspiring to follow. Had this been a US based channel I have no doubt it would have 1 M views per episode, and it would be well deserved at that.
Awesome content. Good to see the final iteration of the oil distributor unit for the all-in-one oil tank. Impressive work and cool design. Look forward to the reviews. Your channel makes Tavarish look like an amateur 😉
When do we get to see the finished oil cooler mounts? This has been one of my favorite channels for the last couple years. Keep up the great work! Looking forward to the next episode.
Love your stuff man, I'm new to old Porsches and damn, this air cooled stuff seems really complicated. I always thought the appeal to air cooled engines was their simplicity.
Love the piece you made for going through the inner wing, I was just thinking something like that would be just the job and then you made one. Came here after Phil recommended you from drift works. Watched up to this point and loving all the work and design!
Amazing content, driftworks recommended this channel and ive seen this build from episode 1 today, amazing amazing work!! Will watch rest of videos tomorrow!!
Really enjoying your vids. A couple of more or less trivial items: - it obviously varies quite a bit based on real world configuration, but in general you are absolutely correct in that fans do nothing over roughly 35kph - they simply cannot move the volume of air that you get by pushing the vehicle through the air. - IIRC, I remember reading somewhere that starting with the 964 the chassis metal was stamped to accommodate RH as well as LH fuel fillers. It was never used till the 996, tho. - A couple of thoughts on the cooler positioning (though I assume it is too late now for you to change anything...): as you surely know, in later cars the radiators are at 45° angles (or thereabout). This has several advantages including the fact that you are not changing the direction of flow 90° twice and thus improving airflow and you can also direct the exit air behind the front wheel and into the brakes. This was done on the 996/7 GT2/3s (not sure about the 991/2s especially with the fender air exits). While the air may be somewhat warmer than ambient, it is a huge amount compared to what is usually ducted to the rotors and works quite well. Obviously this is also dependent on what you are planning with aero in general. - You might consider having hard lines bent to go between the tank and the coolers. You have the potential to save a not insignificant amount of weight vs hoses. - And lastly, wouldn't it be easier (and even a few g lighter) to simply bond very thin sheets of CF to your cooler support frames rather than all those individual plugs? Just curious... I am impressed with your work. Keep it up. I am hoping to finish my 997 GT2RS "tribute" build this spring. It would be cool to do a meet at the 'Ring sometime.
Thank you for your great comment and great feedback! Some thoughts from my side! -I really hope I'll do fine without the electric fan. With a cool down lap and an air-cooled car (with a constant fan) I believe it will also do fine as I enter the pit. -Good info on the filler. It's exactly in that location so it could have something to do with that for sure. -I played around with so many different cooler positions that I cannot remember all of them now. I do agree with your comment and with what I know now I'll revisit a more flat forward facing position to see if I can make sense of it again. The manufacturing technique and the vertical stiffness plays in a bit, but again I'm curious to revisit it again as it would have some good benefits. -I disregarded hardline previously as I believe I would still need hoses for both ends and it becomes a lot of couplings and fixation points. I do like the idea of hard lines though! -The reason I went for the printed inserts was really because I can make them at home and it's very easy. The design is made so that it fits exactly in place and cannot pop out. The material will likely be Nylon or CF infused Nylon which is incredibly strong and durable. Sheets of CF would work just as well and that's how the design actually started ;-) Hope too see you at the Ring once the car is done!
What is more important with oil or water cooling systems is the fore and aft ducting and sealing . The ducting in must enable the air to hit the core at 90° and using Bernoulli's Principle . The same with the ducting out in order to accelerate the airflow out to an area of the matching speed of airflow over the vehicle . So we end up with an opening at the front of the vehicle around 30% of the area of the radiator that flows to hit the core at 90° and an almost identical duct out to the bodywork . Using 2 in this instance you could take the advantage of incorporating the coolers into 'air curtains' at each end of the bumper and exit to the airflow in front over the outside of the front wheels which will reduce frontal drag as well as supply air to each radiator . The increased efficiency will result in smaller oil coolers and lighter weight .
Thanks for the feedback. In the end I redid the whole thing and put the coolers down facing diagonally forward. I don’t know why I wasn’t able to get my mind around that while filming it. There are some photos of the final piece in aluminum on my Instagram.
@@islandworks Hi ! I've just found this channel so made some comments as they've appeared . The method you changed to is common on Formula 2 sidecars which I am building at present ( designed by myself ) but the rads are angled forward .Although the top teams get the ducting correct on the inlet side they have no ducting at the rear which is critical for good recovery .The hot air just finds its own root around other stuff behind the rad and cooler . These things tend to have a continuing overheating problems . The common cause of a DNF . Best wishes .
This might be an area for further improvements. I’m just hoping I get enough out of it to keep it regulating to a consistent temp. Previously it was not enough with the original cooler (combined with incorrect pre-ignition) causing it to climb continuously.
If you flipped the coolers so the ports face the front they would give you all the space you need between them and the tyres, better protection and very little extra length of hose. 👍
That is actually how the final version looks. If you check out my Instagram (islandworks_motorsport) there are some images of it there 👍🏻 Initially I was not able to turn it that way because I was looking at larger coolers and it took me a while to circle back to that....🤣
Thanks for the feedback! More can be done to optimize the flow and direct it through the coolers. The principle I’ve used is that the pressure build up inside the “box”/console will be greatly higher than the other side of the cooler which in turn will drive the flow. This is similar to the original coolers. I’ll see once I push the car hard if it’s enough or if I need to tweak further!
I was just rewatching your videos and I asked myself why not use a sequential gearbox? I am not a mastermind in mechanics but it looks like a better choice? Correct me if I'm wrong. Ps: is the Singer porsche also using a sequential F1 shifter type?
@@sailrockpaperscissors8261 I’ve finished it inside my head, but not in the car. It will be one more mount on the top strapped to the strut brace with a P-clip
Great kraftwerks! Thanks for sharing the 3D level up. How did these Setrabs hold up. I've found they are too easy to damage and don't flow well for the larger oil pumps. I teamed up with Ravi at CSF for a line of oil cooler cores for Porsche and Motorsport. Would have shared sooner but just discovered your vids. Hope to see more of your work and connect. Best from Euro Parts West, Scottdale, AZ USA.
I’ve not had a chance to try it in real life yet. Setrab is a popular choice over here and easily available. I’ve adjusted the consoles after I made the video so that they are shifted forwards. More info on that on my Instagram.
@islandworks Nice, I'm sure the Setrabs should be good as they run perpendicular, so not likely they take a stone puncture. I've got a 2x OE cooler stack grafted to each other. They work well like that in the factory envelope. Beyond that we copy the Turbo S Auxiliary cooler kit in series for front center left mounting (uses m26 unions). The CSF core we run is about 65% larger, so they work well.
My mind is blown by your approach for this build. All the other channels are about welding, grinding and traditional fabrication. Your take on this build is refreshing and so advanced. 👌🏻🔥🤯
It was a really fun project making those oil cooler consoles! Thanks for the comment!
I really like the puzzle piece concept. It’s high precision and really flexible in design. 👍
If you are combining carbon fibre and aluminum make sure to protect the aluminium against corrosion. Sealing the cutting edges should also help. You might want to think about how much the cooler and the oil inside (weight) will stress the the brackets. Aluminum is not very resistant against fatigue. This construction might see a lot of acceleration coming from the suspension especially on a sports car.
Thank you that is great feedback. The covers I had now are plastic and my plan is to make them out of carbon fiber infused PETG which is a reinforced plastic similar to a plastic bottle.
I’ll do a stress analysis to be safe and it’s a good idea to add a few Gs to take a rough ride into account! 👍🏻👍🏻
It would be nice if you could explain your assumptions and the results of the analysis here on your channel.
I’m always running up against the episodes becoming too long and some of it does not make it. For the cooler sizing what I did was to use the tables provided by Setrab and try to make a relative comparison with the cooler I had. In the end I had to assume thing such as the flow through speed and an average rpm at which the oil is being pumped around. What I found in the end is that the new coolers require a bit higher pressure difference on the air side but would otherwise give the same or better.
In the end I will have to test it and if I find I need more I will go to the Setrab STD 634.
I’ve also had a discussion with the people at Setrab to make sense of some of my logic.
Please feel free to ask any questions as I’m happy to share or email me if that’s easier.
@@islandworks Oh well, I had the stress analysis in mind when I asked the question. But this answer is interesting as well 😃
Aha! I’ll share the analysis on Instagram once I get it done ;-)
Islandworks_motorsport
I'm no engineer but I'm really enjoying this build and especially the thought processes that go into it.
Thank you Tim! I’m looking forward to some more time in the garage!
This guy is on another level!
Glad to see you back enjoy your videos
I’m happy to be back! Thanks for watching!
Wow wow wow, this whole build is so impressive and inspiring to follow. Had this been a US based channel I have no doubt it would have 1 M views per episode, and it would be well deserved at that.
I’m looking forward to that 1M mark! Eventually the algorithm might find my channel and give me a push!
you are on a different level - no one does this kind of stuff in their garage lol.
I started small and as I tried more and more things I also saw that a lot is possible as long as you put your mind to it 👍🏻
Awesome content. Good to see the final iteration of the oil distributor unit for the all-in-one oil tank. Impressive work and cool design. Look forward to the reviews. Your channel makes Tavarish look like an amateur 😉
When do we get to see the finished oil cooler mounts? This has been one of my favorite channels for the last couple years. Keep up the great work! Looking forward to the next episode.
I’m looking forward to that piece as well! There is not that much left now so should be coming in one soon I hope as long as I can get the time.
Love to watch this. Greets from Germany - Munich .
Thanks and I hope to drive it in Germany soon!
@@islandworks you are welcome. I always have a cool beer in the fridge . And the roads here in Bavaria are just right to test the performance.
Love your stuff man, I'm new to old Porsches and damn, this air cooled stuff seems really complicated. I always thought the appeal to air cooled engines was their simplicity.
It’s got a beautiful complex simplicity to it
Love the piece you made for going through the inner wing, I was just thinking something like that would be just the job and then you made one. Came here after Phil recommended you from drift works. Watched up to this point and loving all the work and design!
You sir, are a DIY inspiration to all gearheads.
I’m happy to be a gear head! Thanks!
Amazing content, driftworks recommended this channel and ive seen this build from episode 1 today, amazing amazing work!! Will watch rest of videos tomorrow!!
Excellent design work.
It turned out really well and the process worked really well!
Love to watch because of the great engineering that goes in to every piece.
Very interested in the weight distribution at the end.
WOW! Love your build and eye for details! Jette bra! Greeting from Norway!
Great to see that attention to details. Looking forward for next part.
I just love watching this build!
Great work and nice editing Jonas!
Thanks Jörgen!
Next level build
Amazing engineering!
Thanks!
Really enjoying your vids. A couple of more or less trivial items:
- it obviously varies quite a bit based on real world configuration, but in general you are absolutely correct in that fans do nothing over roughly 35kph - they simply cannot move the volume of air that you get by pushing the vehicle through the air.
- IIRC, I remember reading somewhere that starting with the 964 the chassis metal was stamped to accommodate RH as well as LH fuel fillers. It was never used till the 996, tho.
- A couple of thoughts on the cooler positioning (though I assume it is too late now for you to change anything...): as you surely know, in later cars the radiators are at 45° angles (or thereabout). This has several advantages including the fact that you are not changing the direction of flow 90° twice and thus improving airflow and you can also direct the exit air behind the front wheel and into the brakes. This was done on the 996/7 GT2/3s (not sure about the 991/2s especially with the fender air exits). While the air may be somewhat warmer than ambient, it is a huge amount compared to what is usually ducted to the rotors and works quite well. Obviously this is also dependent on what you are planning with aero in general.
- You might consider having hard lines bent to go between the tank and the coolers. You have the potential to save a not insignificant amount of weight vs hoses.
- And lastly, wouldn't it be easier (and even a few g lighter) to simply bond very thin sheets of CF to your cooler support frames rather than all those individual plugs? Just curious...
I am impressed with your work. Keep it up. I am hoping to finish my 997 GT2RS "tribute" build this spring. It would be cool to do a meet at the 'Ring sometime.
Thank you for your great comment and great feedback!
Some thoughts from my side!
-I really hope I'll do fine without the electric fan. With a cool down lap and an air-cooled car (with a constant fan) I believe it will also do fine as I enter the pit.
-Good info on the filler. It's exactly in that location so it could have something to do with that for sure.
-I played around with so many different cooler positions that I cannot remember all of them now. I do agree with your comment and with what I know now I'll revisit a more flat forward facing position to see if I can make sense of it again. The manufacturing technique and the vertical stiffness plays in a bit, but again I'm curious to revisit it again as it would have some good benefits.
-I disregarded hardline previously as I believe I would still need hoses for both ends and it becomes a lot of couplings and fixation points. I do like the idea of hard lines though!
-The reason I went for the printed inserts was really because I can make them at home and it's very easy. The design is made so that it fits exactly in place and cannot pop out. The material will likely be Nylon or CF infused Nylon which is incredibly strong and durable. Sheets of CF would work just as well and that's how the design actually started ;-)
Hope too see you at the Ring once the car is done!
What is more important with oil or water cooling systems is the fore and aft ducting and sealing . The ducting in must enable the air to hit the core at 90° and using Bernoulli's Principle . The same with the ducting out in order to accelerate the airflow out to an area of the matching speed of airflow over the vehicle . So we end up with an opening at the front of the vehicle around 30% of the area of the radiator that flows to hit the core at 90° and an almost identical duct out to the bodywork . Using 2 in this instance you could take the advantage of incorporating the coolers into 'air curtains' at each end of the bumper and exit to the airflow in front over the outside of the front wheels which will reduce frontal drag as well as supply air to each radiator . The increased efficiency will result in smaller oil coolers and lighter weight .
Thanks for the feedback. In the end I redid the whole thing and put the coolers down facing diagonally forward. I don’t know why I wasn’t able to get my mind around that while filming it.
There are some photos of the final piece in aluminum on my Instagram.
@@islandworks Hi ! I've just found this channel so made some comments as they've appeared . The method you changed to is common on Formula 2 sidecars which I am building at present ( designed by myself ) but the rads are angled forward .Although the top teams get the ducting correct on the inlet side they have no ducting at the rear which is critical for good recovery .The hot air just finds its own root around other stuff behind the rad and cooler . These things tend to have a continuing overheating problems . The common cause of a DNF . Best wishes .
This might be an area for further improvements. I’m just hoping I get enough out of it to keep it regulating to a consistent temp. Previously it was not enough with the original cooler (combined with incorrect pre-ignition) causing it to climb continuously.
If you flipped the coolers so the ports face the front they would give you all the space you need between them and the tyres, better protection and very little extra length of hose. 👍
That is actually how the final version looks. If you check out my Instagram (islandworks_motorsport) there are some images of it there 👍🏻 Initially I was not able to turn it that way because I was looking at larger coolers and it took me a while to circle back to that....🤣
Awesome work again 👍
Thanks Mikko!
Cheers to you sir. You should definitely think of building and designing 964 porsche street and race cars.
Jonas, this is just fantastic, where you were when my 964 had a full overhaul😅… ? Kanon👌 hälsn, 🇫🇮
I was likely in Sweden thinking about lateral ways of rebuilding my car ;-)
Great work buddy, but you have to work faster, I can`t wait for final result ;-). Greetings from Germany!
I also can’t wait! I just wish I had more time!
finally new video!! keep going!
wow!
Aerodynamicly speaking i would have desigend a diffrent inside to the cooler mount. Maybe print it and add a layer of Carbon.
Thanks for the feedback! More can be done to optimize the flow and direct it through the coolers. The principle I’ve used is that the pressure build up inside the “box”/console will be greatly higher than the other side of the cooler which in turn will drive the flow. This is similar to the original coolers. I’ll see once I push the car hard if it’s enough or if I need to tweak further!
I was just rewatching your videos and I asked myself why not use a sequential gearbox? I am not a mastermind in mechanics but it looks like a better choice? Correct me if I'm wrong.
Ps: is the Singer porsche also using a sequential F1 shifter type?
I would love to stick a sequential Sadev SL90 in there but they are very costly. It’s on the future upgrade list though!
Have I seen it right.
You are using NX as CAD?
Great fabrication. Are you putting in fans?
No fans! Car will not stand still much
@@islandworks did you finalise the mounting for the oil tank ?
Interested in a lot of the bespoke parts you have done for my build
@@sailrockpaperscissors8261 I’ve finished it inside my head, but not in the car. It will be one more mount on the top strapped to the strut brace with a P-clip
That's going to be too hot for the trunk area. Are you thinking a safe area from accidents?
It’s quite common to have the oil tank in the frunk for 911 track cars. What are you concerned with?
@@islandworks It's just a lot of heat in there.
Can you maybe also add your Instagram account and website link to Description next time? It will be easier for us to find you there.
Great idea!
Garage build... more like microfactory lal
Great kraftwerks! Thanks for sharing the 3D level up. How did these Setrabs hold up. I've found they are too easy to damage and don't flow well for the larger oil pumps.
I teamed up with Ravi at CSF for a line of oil cooler cores for Porsche and Motorsport. Would have shared sooner but just discovered your vids. Hope to see more of your work and connect. Best from Euro Parts West, Scottdale, AZ USA.
I’ve not had a chance to try it in real life yet. Setrab is a popular choice over here and easily available.
I’ve adjusted the consoles after I made the video so that they are shifted forwards. More info on that on my Instagram.
@islandworks Nice, I'm sure the Setrabs should be good as they run perpendicular, so not likely they take a stone puncture. I've got a 2x OE cooler stack grafted to each other. They work well like that in the factory envelope. Beyond that we copy the Turbo S Auxiliary cooler kit in series for front center left mounting (uses m26 unions). The CSF core we run is about 65% larger, so they work well.