Dansk SSI's, Surgery Required?

[Stretch32]

I bought a new a pair of JP Dansk SSI heat exchangers and while installing them today I realized the right side heat exchanger will not fit (the left went on with no issues). Basically it's too fat at the air inlet hole (at the rear of the car) and is hitting the right rear corner of the valve cover and cam tower. It's not obvious in the included pictures but it's very obvious when you actually try and mount them to the car. I trimmed some material off the cam tower (not really what I wanted to do) but it's obvious more needs to go before they will seat on their respective exhaust flanges correctly. I put an original on just to size things up and it fits perfectly with room to spare. I'm not sure if there's something I can do to make it fit or if anybody else has run into this problem with the new JP Dansk SSI heat exchangers. Any help or thoughts would be appreciated. Thanks,

Stretch

[Haasman]

I would contact the seller. These should be close to a right-on fit.

[frankc]

I have SSIs on my 2.7 and there is no clearance issue in this area, however my SSIs are "pre-Dansk". Is Dansk using the same stamping tools? I can't imagine why they would change that.

The engine is currently out of the car, so I just snapped the photo below of the right exchanger - hopefully this helps. Let me know if you need a different angle.

[Stretch32]

It appears, based on the few pictures I found on the 'net of original SSI's, that there is a change in shape on this inlet when comparing mine. The original ones look smaller and more streamlined for lack of a better term (see picture) which would create the space required to fit properly. The new JP Dansk versions are bulkier in this area it would appear (see second picture of somebody with the same problem). Based on this, trading it out for another one wouldn't buy me anything assuming they're all the the same. I'll call the seller Monday but if this is how the new JP Dansk SSI's are then I would think nobody's right side heat exchanger would fit without modification to the heat exchanger and/or cam tower. I would think this would be a major problem worthy of a correction so I'm wondering if I'm the only one (couldn't imagine I would be) or if others have had the same issues.

Stretch

Pictures from other sites

[Stretch32]

A quick follow up after doing a little more reading, it appears others have noted the same problem on other websites. It also appears that Dansk is not using the original SSI stamping to produce these parts simply based on the differences in the original SSI's to the JP Dansk variants.

I posted a few pictures of the "modification" to the cam tower to try and get the required clearance and of the interference issues between the heat exchanger and the cam tower. You can see where I removed some of the cooling fin on the cam tower to make some room. Any idea if this will hurt anything? I don't think it will since it was just trimming down one of the cast on cooling fins and not any part that is structural. You can also see the notch in the heat exchanger seam I made to clear the valve cover. Some others on the Bird have apparently bent the seam down out of the way to make room. They're also "dimpling" the metal to finish clearing the cam tower with a hammer but I feel like this is a little excessive although it may be the only way short of trying another right side heat exchanger.

Stretch

[beh911]

The right side exchanger does have fitment issues. I have seen it on a 72 and a 73.5 where you point out above, as well as at the back by the oil cooler.
On my 69, both sides went on easily with no clearance issues anywhere.

I wonder if it is related to variances in the manufacturing process or slight differences in engine dimensions year to year?

[Stretch32]

I'm having the same issues as the 72/73 cars you mention to include rubbing against the oil cooler. I'm working with a '71T coupe with stock 2.2 engine. I guess there's a possibility the dimensions at the cam tower/valve cover area could be slightly different.

Were you able to finally get them to fit on the 72/73 cars? If so, what did you do?


Stretch

[beh911]

Moved/removed the flange on the SSI exchanger, didn't touch the cam tower like you did

On rear pushed a dent in to fit around the cooler.

[Stretch32]

Yeah, I regret cutting down the cam tower but I initially thought a quick trim would get it to sit correctly. Do you think cutting down the cooling fin would cause any long term issues?

How did you move the flange on the SSI, did you just use a hammer and dolly of some type or did you cut it loose and re-weld it?

Stretch

[Harvey Weidman]

Yeah, I regret cutting down the cam tower but I initially thought a quick trim would get it to sit correctly. Do you think cutting down the cooling fin would cause any long term issues?

How did you move the flange on the SSI, did you just use a hammer and dolly of some type or did you cut it loose and re-weld it?
Stretch

Stretch32, In my past experiences, I have found it is better to modify the aftermarket part than modifying the Porsche part. Looks like you figured that out. I would have someone fimilar with stainless modify the heat exchanger. Possible heat and ball pein hammer?
In my experience, cutting and welding will require some real expertise......
H