intercooling

[jontysafe]

Things trickling along. Have bought a Borg Warner efr7163 after a lot of research. Car is booked into Nortech for the twin scroll manifold, 3.5" down pipe and exhaust along with custom oil drain.
Alan Docking is coming down to have a look at the car to talk about cooling options.
I've also ordered a lovely billet plenum from Anembo engineering.
I've also been talking to Owen developments about mapping again.

[jontysafe]

Mmmmm expensive parts p0rn

[jontysafe]

Finally after farrrr too much deliberation than was entirely necessary I've bought an intercooler
http://www.turbosbytm.com/intercooler-core-air-air... Tried to buy from Uk dealer but would have been a 8 week wait so found at the Garrett dealer in Spain.
Max made suggestions on end tank design based on old F1 profiles so I actually found out who made them and final design won't be very far different from that. I will post a link.

So onto oil cooling, I would like to use laminova because of space restrictions but can't help going back to the fact there is a low delta T again, like my old charge cooler rad. And an air to oil cooler is as reliable as a brick. Any thoughts?

[jontysafe]

Stevie if you go on their website it tells you which are in stock and which are out of stock, the few cores I looked at though were all in stock.

Shipping has for some reason defaulted to €11.30! That isn`t right as I`ve had an email from them this morning saying for some reason shipping address has defaulted to Spain.

[jontysafe]

This was done by Concept Racing.

[jontysafe]

I'm going to rear mount the engine radiator low in the rear roll bar and use some intelligently designed ducting to ensure it gets enough airflow. No heat soak from engine and I can fit a full size Pro-alloy cosworth rad and fan pack. If I need a supplemental electric water pump then so be it. Somehow doubling the power of the engine and near enough taking away a third of the frontal area of the radiator seemed counter intuitive.
I'm undecided and want to take advice on oil cooling. Either air/oil cooler behind and below intercooler or a laminova water/oil cooler.

Another thing I want to look at is the alternator. Currently have a denso 45amp. If I do need a supplemental water pump will possibly need to upgrade that. Holley lift pump, 044 fuel pump, twin Spal fans and coilpack ignition would need all of that.

[jontysafe]

Speaking to Julian Godfrey today as they have an option. Not cheap as usual though!!

[jontysafe]

Julian has a cnc machined alloy bracket to drop and bring forward any Denso bodied alternator so perfect. Soooo including updated 85amp alternator its £780!!!! Hmmmmm.

I already have a custom bracket so will just try an uprated denso bodied alternator, just have to be careful with sizing.

[jontysafe]

Cooling idea is one born out of simplicity and common sense. Be interesting to see if I do need a supplemental pump. One "specialist" has told me because I'm increasing volume of water it will be needed. Not sure what volume of water has to do with it. It's all going to be about pressure which as we know is a measure of resistance. Can the venerable ford yb pump at enough pressure at idle? Who knows until we try it.

[jontysafe]

I'm going to first try it out for sure without the complication of an electric water pump. With the extra length of lines and the fact the radiator will be raised above the engine then there will be more resistance but will it be enough to need help? I'm guessing probably not. The only issue, if there is one, will be at idle.

[jontysafe]

That's what I'm hoping!

Looking at this oil cooler
http://www.serckservicesmotorsport.co.uk/13-row/se...

With a thermostat set at 95 degrees.
Going to try and fab all this up between me and a few mates.
Stevie, how many amps would you build in for a margin of safety. I have a Holley blue, 044, twin Spal fans, ignition and not much else. To my reckoning that's about 45 amps just there. Although I'm not sure on the amp drain of the fans.

I need to go up a body size on the denso, spoke to Brise today. Think 85amp just in case I do need to go EWP.

[jontysafe]

stevieturbo said:

Mechanical pump will have no problems IMO...

And dont forget, whatever water it may have to push uphill...that same water falls back down pulling some with it.

Just make sure whatever is your highest point....is the remote header with airspace, either that or build it into the radiator somehow.

Air locks will be the only potential problem if not designed right

Yep looking at a header tank above rad, would be nice to find a rad with built in expansion tank that was same size roughly as cosworth rad. As Cossie is cross flow most rads with headers built in are vertical flow.
Zionsville in USA do one for e36 Beemer but again it's all the money in the world.

[jontysafe]

Apparently Julian fits a Toyota 85amp alternator on his RX engines which the bracket fits of course.

We are doing a dummy engine install next week to measure up clearances for alternator, new plenum and throttle body, intercooler and oil cooler and dry sump and pump. Looks like the lower left wishbone mount could possibly be in the way of the pump. Won't know until we try.

Measured up for rear radiator and it looks like an Ultima rad will fit nicely so a little more cooling surface area than a Cossie rad.
Racecar warehouse also have some Bentley Lemans rads which I've asked for sizing on.

The intercooler core I bought is 18inches wide and it turns out the nose cone is 23 inches wide where it will sit so that has worked out nicely with the end tanks.

[jontysafe]

More aluminium goodness!

[jontysafe]

Finished product

Thanks to Dean at Tylah Motorsport. The man is an artist with a welder.

[jontysafe]

I think it looks very "factory" in place.

[jontysafe]

Actual rad install done as well as ducting. Work starting on pipe runs next week as well as Laminova oil cooler (can't fit air/oil cooler), rad expansion tank and dry sump tank.

[jontysafe]

jontysafe said:

Actual rad install done as well as ducting. Work starting on pipe runs next week as well as Laminova oil cooler (can't fit air/oil cooler), rad expansion tank and dry sump tank.

Well that’s all finished and was ages ago but I’ve basically been busy with babies and work!

I really need to speak to engine builder now.