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Air-Cooled Porsche 911 Gets Help With Front Oil Cooler Mods

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Language: en

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welcome to garage time this week I'm
going to show you how to improve the air
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flow on the front oil cooler on this
air-cooled Porsche 911 so you've
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probably heard me talk about the larger
engine in this car and I definitely want
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to upgrade the engine to something
that's higher than three liters that
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does require additional oil cooling even
though these are air cooled cars
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actually a bigger percentage of the
cooling is done through the oil so the
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front mounted oil cooler is very
important and Porsche put a lot of oil
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coolers in the right front fender and
there is some airflow in there but it's
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not the same as a front mounted oil
cooler which sees direct flow due to
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driving you know 50 60 hundred miles an
hour air flow if it's done correctly and
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the ducting is done correctly all that
air has to flow through the oil cooler
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and it's much more efficient so my front
RS bumper is not just for looks it's
00:00:59.430 --> 00:01:03.840
chosen for performance all right the
problem I'm trying to solve today is
00:01:03.840 --> 00:01:08.729
this front mounted oil cooler there
might be room for the oil cooler to
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mount but there's no room for air to
efficiently flow through the oil cooler
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and underneath the car so this stock
latch panel is really in the way so I
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have left this uncut or untrimmed or
unfinished so that I can add a airflow
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duct just like they did in the early 70s
with the RS and the RS are cars before I
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get to work today I wanted to take a
moment to thank you guys for watching
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today's episode marks one year of a
garage fire if you are new to my channel
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welcome my name is Tom and I try to
encourage you to get out in your garage
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and build something I strive for
professional results but I am NOT a
00:01:57.299 --> 00:02:00.570
professional I have learned everything
by doing and and that's what I encourage
00:02:00.570 --> 00:02:12.229
you to do this is my first Porsche 911
and I am still learning a lot
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okay this is the area that I'm gonna be
cutting out and I'm gonna be welding up
00:02:17.510 --> 00:02:21.830
on the top of this here too now this
bracket here appears to be in the way so
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I'm gonna remove this bracket and also
I've already removed most of this
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bracket but I need to remove it all the
way down to this latch panel
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this is roughly the shape that I want to
have it's a curved arc going down into
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this gas tank side support here I'm
gonna put a flange here on the top so I
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don't have to weld a continuous bead
along the top I can just spot weld it or
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seam weld it there from the front it
still doesn't look like much because
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they haven't cut anything out yet I'm
gonna go right to sheet metal on this
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one pretty early because the shape is so
hard to hold with this paper
00:03:48.060 --> 00:03:54.250
okay I've also free-handed a second line
here this this is just kind of a curve
00:03:54.250 --> 00:03:59.260
it's gonna be kind of a bulbous shape as
it comes from the front of the car it's
00:03:59.260 --> 00:04:04.180
gonna you know this is this is the front
it's gonna go out wide and then and then
00:04:04.180 --> 00:04:08.320
neck down at the very end so I want to
have it curved kind of in this direction
00:04:08.320 --> 00:04:12.280
and in this direction plus I know that
it's gonna make the welding a little
00:04:12.280 --> 00:04:16.390
easier instead of putting a flat panel
along this side having a curved section
00:04:16.390 --> 00:04:22.090
is going to keep it some shape and help
prevent the distortion at least that's
00:04:22.090 --> 00:04:27.360
the theory anyways
00:05:04.909 --> 00:05:09.930
I'm having to redo this flange a little
bit to put some curve into it the front
00:05:09.930 --> 00:05:15.449
of the car is not as flat as I expected
it so once it's in metal I'm able to see
00:05:15.449 --> 00:05:19.289
that the gaps there so I'm going to
hammer this flat and then rebend it on a
00:05:19.289 --> 00:05:21.889
new arc
00:05:57.110 --> 00:06:05.310
here's a quick status update that flange
I formed on the bead roller is this
00:06:05.310 --> 00:06:10.860
flange right here it's it's sandwiched
together on that so it's about a I guess
00:06:10.860 --> 00:06:17.160
a 45 degree or so flange and then let me
show you from the inside okay so from
00:06:17.160 --> 00:06:21.090
the inside this is that flange you can
see just a little bit of daylight in
00:06:21.090 --> 00:06:25.140
between here I need to pull it up
tighter with some more clamps but I want
00:06:25.140 --> 00:06:31.050
to have that folded over edge right even
along this folded over edge here which
00:06:31.050 --> 00:06:36.420
is part of the factory edge and I have a
little bit of curve in the the panel I
00:06:36.420 --> 00:06:41.190
just formed it over the bench just you
know using my hands and you can see this
00:06:41.190 --> 00:06:44.940
kind of curved shape here this will come
straight down okay I'm making this
00:06:44.940 --> 00:06:49.710
little test strip so I can get the
length right here without ruining this
00:06:49.710 --> 00:06:53.880
huge piece of metal I don't have a lot
of time invested in this piece of metal
00:06:53.880 --> 00:06:57.960
but I it's the only metal I have I'd
have to go to the store to buy more so I
00:06:57.960 --> 00:07:01.680
want to make sure that by bending this
little strip I have left over I get the
00:07:01.680 --> 00:07:05.970
length right and then I can check it in
three places to make sure I can mark
00:07:05.970 --> 00:07:09.800
this piece here without having to scrap
it
00:08:18.030 --> 00:08:21.740
if it's like right here it's still a
little bit long at least it's too long
00:08:21.740 --> 00:08:29.000
better long then short should I force it
in there
00:08:46.740 --> 00:08:51.879
I'm just reworking these flanges a
little bit to try to get it more even
00:08:51.879 --> 00:08:55.199
with that gas tank panel
00:09:09.450 --> 00:09:15.250
okay here it is the part in the car it's
not welded or anything it's just
00:09:15.250 --> 00:09:20.170
basically holding itself in place just
the spring tension on this thing and it
00:09:20.170 --> 00:09:25.420
fits really well right here and then
over here there's a little bit of a gap
00:09:25.420 --> 00:09:29.500
I'm not too worried I think I can pull
this tighter when I weld it in you know
00:09:29.500 --> 00:09:32.920
this whole thing is flexible and
depending how much curve it has in it it
00:09:32.920 --> 00:09:38.770
really affects this gap but I did trim
this a little too too narrow
00:09:38.770 --> 00:09:44.680
this needs to be a little bit less of a
gap so even if I straighten out this arc
00:09:44.680 --> 00:09:49.600
it's still probably trimmed a little too
far it's just really difficult to try to
00:09:49.600 --> 00:09:55.300
get that perfect all the way across here
I think I'm gonna drill a few holes here
00:09:55.300 --> 00:09:59.740
and put some screws or clecos in here
just so I can have a reference and I'm
00:09:59.740 --> 00:10:05.380
gonna start banking the walls that that
closed out this section and I decided to
00:10:05.380 --> 00:10:09.010
put them in a little bit of an angle
rather than go straight down I think
00:10:09.010 --> 00:10:14.250
I'll do like a 10 degree angle so that
it is a little bit more of a gentle
00:10:14.250 --> 00:10:20.140
shape and then I'm gonna trim this is
very lumpy down here on the floor so
00:10:20.140 --> 00:10:23.710
there's one lump right there one lump
right there and then it gets flat again
00:10:23.710 --> 00:10:27.640
so rather than try to make a wall and
then flange it over all these lumps I
00:10:27.640 --> 00:10:31.420
think I'm just going to cut straight
down and then weld the edges from the
00:10:31.420 --> 00:10:36.730
bottom okay I've taken this scrap piece
of sheet metal and I've sharpened the
00:10:36.730 --> 00:10:43.450
end to a point and I'm I have my digital
level here and I'm just going to trace
00:10:43.450 --> 00:10:50.230
on here the about a 10 degree angle on
this and I've put some dye CEM down on
00:10:50.230 --> 00:10:59.589
the suspension pan so I can trace the
the path so that's 80 degrees right
00:10:59.589 --> 00:11:06.600
there just scratch a little mark
00:11:10.050 --> 00:11:19.610
Edie
00:11:19.610 --> 00:11:23.550
okay I can see the line well enough to
make a cut company the same here this
00:11:23.550 --> 00:11:36.040
side
00:11:36.040 --> 00:11:40.760
okay I think I can get most of this cut
done from the top side using my air saw
00:11:40.760 --> 00:11:44.750
so I'm gonna drill a hole and try to do
most of the cutting from here if I need
00:11:44.750 --> 00:11:51.520
to go underneath and cut I will you got
to drill a hole first
00:13:56.949 --> 00:14:02.839
okay there's a quick status update I got
these side curve pieces in and they are
00:14:02.839 --> 00:14:08.630
tax weld tack welded on the edge and
there's a little bit of a gap there on
00:14:08.630 --> 00:14:12.470
the bottom it but it flexes I can just
tighten it up and then the same is true
00:14:12.470 --> 00:14:21.110
for for this side I have that piece tack
welded in so I'm going to remove this
00:14:21.110 --> 00:14:25.790
from the car and weld this on the bench
I think it's gonna hold its shape okay
00:14:25.790 --> 00:14:32.149
so I'm going to weld these these curved
edges here on the top half here's a look
00:14:32.149 --> 00:14:36.589
from underneath the car and you can see
the welds coming through on that line
00:14:36.589 --> 00:14:43.490
that I want to weld right now and this
is a pretty big mouth more welds right
00:14:43.490 --> 00:14:46.399
there I really like the curved shape to
00:14:46.399 --> 00:14:52.339
this portion here is going to be trimmed
this is overhanging so I'm gonna trim
00:14:52.339 --> 00:14:56.029
that and weld it on to the outer edges
and then the same is true for here this
00:14:56.029 --> 00:15:01.040
is gonna get edge welded and pinch weld
it up here and seam weld it on the
00:15:01.040 --> 00:15:07.610
inside also this flange here is left
long and it's gonna get cut once it's
00:15:07.610 --> 00:15:10.550
welded from the inside that's gonna get
trimmed and make a nice smooth
00:15:10.550 --> 00:15:15.430
transition between here so there won't
be this ledge right there
00:15:46.329 --> 00:15:54.980
just like that now it's one piece so
there's the weld all along the edge okay
00:15:54.980 --> 00:15:59.329
right here is where I accidentally cut
this a little short when I was just
00:15:59.329 --> 00:16:04.429
guessing at the fit so I welded this
little piece on the end and I'm going to
00:16:04.429 --> 00:16:08.929
now try again to trim it to the right
size so this all grind down with a
00:16:08.929 --> 00:16:13.639
grinder and you won't even know it's
there but that's just the advantage of
00:16:13.639 --> 00:16:20.209
being a welder you can always fix your
mistakes on this side I did something a
00:16:20.209 --> 00:16:24.920
little different I actually put a weld
bead on the edge now this is 18 gauge
00:16:24.920 --> 00:16:30.110
metal you won't see a lot of guys try
this this is now obviously pretty thin
00:16:30.110 --> 00:16:35.329
metal but putting a bead on the end
grind it smooth and it just makes the
00:16:35.329 --> 00:16:37.749
part bigger
00:16:57.260 --> 00:17:03.060
ground everything down so the edges are
smooth and filed and I treated the
00:17:03.060 --> 00:17:08.280
backsides of these flanges with the well
through primer and I've also marked my
00:17:08.280 --> 00:17:12.870
seam welds every one inch so they line
up with these seam welds and it'll be in
00:17:12.870 --> 00:17:19.290
the same pattern as everywhere else here
in the in the trunk area so I need to
00:17:19.290 --> 00:17:22.250
fire up the MIG welder
00:17:38.880 --> 00:17:43.440
okay everything's finally fully welded
in I've been laying on my back
00:17:43.440 --> 00:17:48.510
welding upside down with the TIG welder
it's it's actually pretty difficult I
00:17:48.510 --> 00:17:53.039
use a foot pedal and in order to use the
foot pedal when you're on your back you
00:17:53.039 --> 00:17:56.370
got to put it between your knees and
kind of squeeze it so because of the
00:17:56.370 --> 00:17:59.880
close proximity to the wall and all that
I didn't take video of that I know
00:17:59.880 --> 00:18:03.720
you're you're disappointed but it's all
in there and I'm gonna show it to you
00:18:03.720 --> 00:18:07.919
real quick so I wanted to talk about the
patreon page I didn't do a good job
00:18:07.919 --> 00:18:13.500
describing this and I think I'd confused
a lot of people it's not a YouTube
00:18:13.500 --> 00:18:17.580
livestream on Sundays it's really
through patreon it's a private
00:18:17.580 --> 00:18:22.559
membership it's really more of a
conference call a video conference call
00:18:22.559 --> 00:18:28.110
where we spend an hour on Sundays going
over what you want to go over so maybe
00:18:28.110 --> 00:18:32.250
it's your project at home maybe it's
something you saw me do it's really
00:18:32.250 --> 00:18:36.000
above and beyond what you can normally
get in the comments below now
00:18:36.000 --> 00:18:39.570
nothing on the channel is gonna change I
will continue to answer questions and
00:18:39.570 --> 00:18:44.909
comments in the comments section on
YouTube and will continue to post videos
00:18:44.909 --> 00:18:49.350
every Saturday and that content is
completely free if you want to do more
00:18:49.350 --> 00:18:53.789
like a 10-minute conversation about your
question that's what the livestream is
00:18:53.789 --> 00:18:59.159
on Sunday we're going through and you
can email me in advance I send out the
00:18:59.159 --> 00:19:03.179
link prior to the phone call if you want
to send pictures documentation drawings
00:19:03.179 --> 00:19:08.309
sketches ideas I look at those we spend
you know maybe 10 minutes per person and
00:19:08.309 --> 00:19:13.140
we go in depth other people can jump in
and help there's other people on this
00:19:13.140 --> 00:19:17.280
community that are more knowledgeable
than I am so it's a great way to get
00:19:17.280 --> 00:19:21.770
your individual questions answered with
someone who you know can do the work
00:19:21.770 --> 00:19:26.760
that's the benefit it's on patreon.com
I'll put the link in the description
00:19:26.760 --> 00:19:32.429
below it's 5 bucks 5 bucks for the month
so that gets you 4 sessions hour-long on
00:19:32.429 --> 00:19:37.620
Sunday and we talk about whatever you
want to talk about so 5 bucks come on
00:19:37.620 --> 00:19:41.309
guys let's get it done I want to know
what you're working on you have full
00:19:41.309 --> 00:19:47.549
access to me and email all that we get
work done on Sundays so I think you'll
00:19:47.549 --> 00:19:51.330
find it beneficial please take a look
and join that way but don't look for it
00:19:51.330 --> 00:19:55.640
on YouTube sorry if I can whew
people it's really a video conference
00:19:55.640 --> 00:20:00.770
call consultation with me so please take
a look at it and let me show you what we
00:20:00.770 --> 00:20:04.480
got done peace

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