After installing the new intercooler plus all the additional stuff, I suffered boost problems, the car only gave 0.4-0.5 bar of boost at best. Well, I tried many different things to cure the problem, but there was no change.
Until today! I repositioned the APC solenoid valve, made a new bracket for it and connected the solenoid pipes with 6mm silicone hose. I also fitted new Bougicord ignition leads, and now the car really moves!

As for the intercooler and its effect, I can now tell that without any other performance modifications, a big front-mount intercooler with good flow design along with bigger pipework, the effect really is instantly noticeable. I can't tell how many hp I've gained, but the difference is definetely there.
And the lag isn't bad at all, even though the piping is a lot longer than the original.
I guess the less restrictive flow path helps here too.
Next I'm going to modify the exhaust system a bit, and make a DIY water injection, plus tweak the APC further, and see where that gets me. Anyway, this is all just temporary tweaking, something to keep me happy while I can't yet afford to do the whole engine job.

What kind of intercooler did you fit ?

Here's a picture...
./uploads/IC_small1.jpg

look very nice...

How is the Depth of the New intercooler V's the old one?

Have you got any measurements on the size differences? New V's old.

Regards

Here's a measurement comparison:

My new IC (original)

Core width: 325 mm (220 mm)
Core height: 303 mm (200 mm)
Core depth: 64 mm (64 mm)

Core volume: 6302 mm2 (2816 mm2)

You'll be giving us a writeup on where to get the parts and how to fit them, right? :smile:

Yep! :smile:

An article will appear at http://www.turboteameurope.com
-just as soon as I get it ready. There you can see larger pictures along with design tips and a walk-through of the installment.
I hope it's going to be of interest for Saab lovers, so I'll do my best!

Niko,
I think that with warmer France weather you would suffer from overheating with such an FMIC.

Well, 30 degrees Celcius hasn't caused any problems for me at least.
And the company from which I ordered the IC informed me that they never once had any problems with IC-fitment-related overheating.
Of course, the radiator needs to be OK, but that's a must anyway. In my installment, I even left some space for free airflow above and on the sides of the IC unit.

And if there still is overheating, then there's one effective cure: Remove a meter's lenght of rubber seal from where the bonnet meets the panel below the windshield, and then bend the panel where the rubber seal used to be, downwards, to allow air to escape from below the bonnet.

Saab 900 Racing drivers use this trick in their car, but overheating isn't the problem they are tackling - it's to reduce temperature in the engine compartment for denser intake air plus better through-flow for the intercooler.

There are many multi-hundred horsepower turbo cars that have their radiator completely covered by a thick intercooler, and they don't suffer from overheating. For that matter, if an intercooler is to be efficient, it needs to be able to allow lots of airflow through itself, and this again contributes to lessened hindrace of airflow to the radiator.