Air to water intercoolers - educate me

[chuntington101]

itiejim said:

eliot said:

What do you mean by this?
BOV is to release pressure when you snap the throttle shut and the compressor is trying compress air against a closed throttle.

My mistake, I'm an FI newbie, I think I meant a wastegate? Effectively, there is no bleed for excess pressure created after the compressor, therefore I wish to lose as little of what is generated as possible.

From memory isn't the throttle body in front of the supercharger on these? Is so there is no need for a BOV!

[itiejim]

Indeed it is.

[chuntington101]

Also for 260bhp do you really need a high end core? Why not use a decent sized eBay unit or say a EVO unit.

[227bhp]

chuntington101 said:

Also for 260bhp do you really need a high end core? Why not use a decent sized eBay unit or say a EVO unit.

^^ This, you can buy a decent one on Ebay for circa £100.

[jontysafe]

when a decent core is only €159 plus VAT why would you do ebay Chinese generic?

Get it tigged up for £250 ish I would have thought.

[eliot]

itiejim said:

Indeed it is.

Ah ok - then you don't need a Blow off Valve.
Perhaps you need a Suck Of Valve instead!

[stevieturbo]

chuntington101 said:

Also for 260bhp do you really need a high end core? Why not use a decent sized eBay unit or say a EVO unit.

If space is limited...and you cannot go big, then yes use a good core.

Although when they work so bloody well....I'd say use the Garrett every time. Do the job once.

[chuntington101]

stevieturbo said:

chuntington101 said:

Also for 260bhp do you really need a high end core? Why not use a decent sized eBay unit or say a EVO unit.

If space is limited...and you cannot go big, then yes use a good core.

Although when they work so bloody well....I'd say use the Garrett every time. Do the job once.

Good point Steve. Also didn't realise the cores were that cheap!

[itiejim]

Thought I'd update this thread with a result (just to prove that people's advice is listened to)! I bought the Garrett intercooler core recommended and went and had a nice chat with my friendly local aluminium fabricating genius - Dave Cale in Malvern. I looked at the advice from Garrett regarding end tank design and, incorporating that into the space constraints, Dave came up with what you see pictured below (just the final welds and inlet / outlets to go on).

Thanks for all the advice folks, hopefully the IC will work well, but if it doesn't I have a stunning bit of aluminium fabrication to gaze at anyway

[jontysafe]

That looks a lovely job

[crossy67]

That looks lovely.

[NotNormal]

Looking good, however make sure you put some beads on those end tubes otherwise you''ll be blowing the hoses off when you come on boost.

[itiejim]

The end pipes are now on (and have beads)!

[227bhp]

Very skilled work, looks very impressive, i'd like to know how that is done.

[itiejim]

Thanks. He makes wooden bucks to shape the aluminium over. I think I've got another photo with a picture of them in the background. He's an ex-Morgan body man who I came across a year or so ago and the quality of his work is outstanding. He's currently building bodies for a Bugatti Atlantique and a Cobra, both from scratch. When I saw the artistry I just had to have a piece of his work on my humble, home brew Spitfire. So glad I did.

[itiejim]

Picture with wooden bucks in the background.

[turbotoaster]

you will find that your supercharger does one of two things, either is nice and linier boost up to 10psi by 7000rpm or makes 10psi by 5500rpm then drops off.

Its happened to a few of us running these chargers and we arnt really sure why.

i assume for the power your after that its a vvc or vhpd engine you have?

If you are building a bottom end for it, allow a bit more ring clearance, circa 20 thou on the top ring which will mean you have more potential for expansion if your looking for more power in the future(coming from someone who has turned his stock k series bottom end up to 340bhp)

[itiejim]

Thanks for the input, I'll take your advice on the ring gaps. Should I keep the second ring gap as per OE spec?

I'm building it as a VVC with Westwood liners and the Turbo Technics pistons and rods. I'll probably get the crank nitride and the lot balanced.

Are you running 300+ bhp through a totally standard bottom end?

[anonymous-user]

I/C looks good!

(Only thing i would have done is gone for a"race track" cross section in the blend between the round entry tube and the square matrix inlet/outlet in order to get a more consistent Rate of Change of hydraulic diameter)

[itiejim]

High praise indeed, thanks

I don't really understand what you mean by the racetrack profile, but if we're talking about nth degrees of improvement I suspect I can live with it as it is.

Having said that, if you can explain how it might be improved I'll certainly feedback to Dave, the fabricator, for inclusion in future projects. Thanks to all for the input on this project.