Thread: New intercooler.
08-15-2011, 07:32 AM #1
I knocked this up a few weeks back now.
I decided that seeing Ill be able to log intake temps using the Haltech I would build a new intercooler to compare with the XS I have now.
I want to see what effect it has on temps, fueling and if I can make more power/run more timing safely with this cooler.
I brought the core from a company that produces ratiators/intercoolers/charge coolers for alot of race teams and industry in the UK. it measures 100mm x 100mm x 300mm, which is the same hieght and width as the XS I have now but 30mm longer.
I fabricated all the tanks myself and had a guy at work do the welding for me.
You will notice that I have tapered the feed point and the tank, I feel that even distribution of water through the core is as important as even air flow, I feel that its less efficient having one part of the core running colder then the rest. Take a look at F1 radiator end tanks, they certainly are not letting the water find its own way!!!
It will run 13mm line in the 13mm out and a 8mm bleed which is restricted to 4mm. the cooler will have its own feed off of the pump and then go straight over board, I wanted this so I could play with flow/pressure without effecting anything down stream I.E engine/exhaust temps.
The air in/out are the same diameter as the SCer and TB so no up and down in size, I also have something interesting in mind for the boost pipes that will mean no joins or extra clamps.
One big difference straight away is wieght this thing is well under half the wieght of the XS!!! Dry for Dry!
I will be running the XS I have now untill im happy with the tune in the Haltech, then Ill make the change and see what we get.
Im happy that I will see lower AITs, similar boost numbers, need more fuel and run more timing safely.
08-15-2011, 07:35 AM #2
08-15-2011, 07:39 AM #3
Just some info that might help you have been involved in very many intercooler set ups in many race cars and all tested on the Dyno.
A good company in the UK to speak to is Marston Aerospace not to be confused with Marson radiators.
The Aerospace side is where all the testing and action is happening and for a water to air cooler you need a different core than you would use for an air to air cooler.
Tested very many of these to get the results.
Just seen the picture looks a great job
08-15-2011, 07:41 AM #4
Pics.. not in any order but you can see what Iv been doing
08-15-2011, 07:48 AM #5
that looks very interesting and promising. let us know your results!
08-15-2011, 07:49 AM #6
08-15-2011, 08:38 AM #7
Looks similar to what speedfreaks does to an xs cooler. Should be great. Is the core suppose to be better than an xs core?
08-15-2011, 09:07 AM #8
Yes the core is a specific liquid to air core. The water "bars" are 1/3 the size of the water "bars" in the XS coolers, meaning with the same size core there is much more fin surface area for the boost to travel over.
Also if you look at the fins closely they are "luvred" so the air passes thru them as well as along thier length. You might not be able to see that in the pics.
The XS coolers are made using air to air cores with water tanks on either end, on the most part the XS is extremly good esspecially for the money. I dont know that mine will be any better!! If you look at the water passages in the XS they are huge, this means that less of the water is in contact with the bar taking on heat, the passages need to be huge in a Air to Air intercooler because of presure drop.
Im lucky that I built it for not too much money because of facilitys at work. It took a lot of time to complete tho. Thats where the money is if you were to build these.
Ill certainly up date here once I have run it and got some good evidence of any pro's and con's.
08-15-2011, 09:10 AM #9
08-15-2011, 09:18 AM #10
One thing you can do is take the cap off of your car radiator and take a look at the bars inside then compare them to the bars that are in the XS, also take note of the amout of fins in comparison to the XS coolers.
Louis did some real good testing a while back with a XS the 2008-2010 255 ICer and one of his own design, not sure what core he used tho. in short the XS worked very well up to a certain amount of boost and for a small amount of time, if you went hard for a longer period of time the temps just went up and up. The "X" intercooler was better but had some shortfall, cant remember. Then his ICer was keeping 20+PSI cool and for as long as you wanted to run, this is the key for performance over a longer period of hard running.
Just take all the work Breon did with the ICer he has to get rid of heat soak. The only thing I wouldnt personly like about that ICer is volume. Thats another reason I made the tanks on mine as small as I felt they could be. Throttle response for me is vital.
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