The 3rd Radiator DIY by Carrera Mike was excellent and got me thru my own install: http://forums.rennlist.com/rennforum...carrera-s.html
While the front fascia was off I took the opportunity to also clean out my two radiators. It's interesting the type of crud you find tucked up in there.
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After removing all this stuff with a paint brush and washing to clean I then worked to straighten out some of the bent in radiator fins. I found that a few wooden toothpicks worked best for getting in between the bent fins.
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Cleaned and applied 303 to all rubber and plastic parts for good measure while I had everything disassembled.
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I cut the appropriate vent slots into the bottom of the front fascia for the 3rd radiator airflow. And fabricated some grills to protect these slots from any debris getting up into the 3rd radiator from underneath.
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The final product is a 3rd radiator right above the vents with protective grills.
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Button her back up and you're good to go. Well until I powered her up... make sure you check the wiring connection for the lighting before you seal her up. Found out the hard way that the wiring bundle connector needs to be pushed together much harder than I thought. You should hear a click when it's seated properly. Otherwise the car will throw error codes re the side markers even though the headlights work. I also replaced the amber side markers with white ones which meant a bit of troubleshooting to get to root cause between the new side markers and wire connector.
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Instead of just filling up the 3rd radiator with coolant I took this opportunity to flush some of the car's coolant. I got 3.5 gallons out by draining the coolant from both ends - the coolant plug under the engine and the plugs at the front where the 3rd radiator connects to. Note that the entire system should hold slightly over 8 gallons but the only way to get it all out requires taking all the panels under the car off and disconnecting all the numerous radiator related hoses so 3.5 gallons was good for now. Plus I plan on replacing the water pump soon which will be another opportunity to flush/cycle some more out.
To refill the system I used an Airlift 550000 and the following DIY from Pedro's Garage http://pedrosgarage.com/Site_3/Flush...nt_System.html The airlift suctioned 4 gallons of 50/50 mix of the new Porsche coolant into the car. The additional radiator took up another .5 gallons beyond the original 3.5 gallons that drained from the car originally. I did several test drives since with the burp value open, however, the system seems to be full as I have not had to add anymore coolant.
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Observations: I've done a few spirited drives thru the Hill Country near me and here are some of my findings so far. It was 91deg today. Starting out the car takes an additional mile of warm up driving before it reaches 200deg(operating) oil temp. In the pass the 1st 2 miles was enough to get her to operating temp. And instead of the typical 225deg oil temp once I got her on the roads for a bit it stays right at ~210/215ish deg. After some higher rev. runs, 4K-6K rpm, up and down some hills I started seeing the oil temp get as high as 250deg. In the pass the car was hitting 275deg+ after these types of hill country runs. Finally, cooling back down to 210-225 was fairly quick. This Porsche mod seems to have some legs to it and I'm looking forward to driving her during our hot TX summers this year.
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