Intercoolers to front mount or not to front mount?

[Liquid Knight]

I have a Fiat Coupe 16V turbo project going on at the moment and I'm considering a front mounted intercooler.

The car will be for road and track use and even though she's a rare old beast (one of only fifty left) she's been clocked in the past so a full restoration would be futile.

I'm planning a few modifications to the engine but the intercooler is an option taking a lot of consideration so I thought it best to ask.

Okay the basic idea is larger intercoolers mounted directly in the air flow of the car reduce the air temperature more than standard items. Basic physics. But the distance between the turbo and throttle body can be as much as doubled thus increasing lag.

Is there definitive proof that a front mounted intercooler is beneficial or purely cosmetic?

Three options.

Standard - may not bode well with other planned modifications.
Standard fit but better core etc - Would be more efficient and the distance between the turbo and inlet unchanged.
Front mounted - worth the faff or naff?

[Boosted LS1]

Imo, the main thing is to have a good low pressure region for the air to exit into. If you achieve this it'll fly through the cooler. I'd suggest keeping the cooler up front, buy quality if you can or something from another OE vehicle? I wouldn't be to bothered if pipe runs were a bit longer then original.

[Liquid Knight]

That's a very good point. A good core and decent flow rate will be better than a larger surface area. It's a balancing act between flow and cooling effect.

[Boosted LS1]

You can also build exit ducting behind the core so the airstream can avoid the engine.

[Liquid Knight]

Boosted LS1 said:

You can also build exit ducting behind the core so the airstream can avoid the engine.

Direct from the cooler to the inlet thus shortening the distance?

[magooagain]

The Mitsubishi evo 6 front mount inter coolers have been used in the past on 16vt. A pro alloy custom one may be the way to go but expensive I imagine.

[Liquid Knight]

I'm not thinking cheap eBay stuff that was duct-taped to the front of a Fiesta in 2002

Aluminium core standard fit Integralle spec'...

http://www.ebay.co.uk/itm/Intercooler-upgrade-Lanc...

...although that look completely standard with aluminium top and bottom instead of plastic it could do the trick or...

http://www.ebay.co.uk/itm/Pro-Alloy-Intercooler-Ki...

...a decent front mount kit. Relocating the air filter is an consideration as it's not getting much in the way of flow behind the headlight. I was thinking of functional louvers but that could be a pedestrian hazard for Mr MOT.

Besides Speed holes was patented by Homer Simpson.

https://www.youtube.com/watch?v=whnms4CLJys

[Evoluzione]

Liquid Knight said:

I'm not thinking cheap eBay stuff that was duct-taped to the front of a Fiesta in 2002

Aluminium core standard fit Integralle spec'...

http://www.ebay.co.uk/itm/Intercooler-upgrade-Lanc...

That's about the same size as the one you're taking off so not much advantage to be had there.

This is what you need:

http://www.ebay.co.uk/itm/TURBO-INTERCOOLER-BAR-PL...

And this:

http://www.pistonheads.com/gassing/topic.asp?h=0&a...

And this:

http://deltaparts1.blogspot.co.uk/2010/03/intercoo...

But before that you need a plan because you don't seem to have one and will come unstuck if you don't have:

A realistic power output goal.
List of parts needed to achieve that.

They are very expensive to make into track cars and aren't that good anyhow.

Edited by Evoluzione on Monday 6th June 22:27

[Liquid Knight]

I'm not the most organised.

I'd like to get the car rolling first and base dynographed to make sure nothing is going to go bang. Also the car has allegedly been tuned to stage two by FC Performance. If that's the case I have the inlet cam' from an N/A (for more duration and top Guy Croft's list of things to do) car to compliment the existing stuff (if the car is stage 2 tuned).

In theory at least.

Intercooling isn't a priority right now but could compliment things later.

I'm not trying to set the world on fire but a good usable car with a bit of poke for the track would be good. I know there are plenty of quicker platforms around but this is what I have and despite the Bangle angles it's still one of the best looking cars of the last twenty five years.

[Liquid Knight]

Instead of in one end out the other and seven feet of pipe how about something like this?

http://www.ebay.co.uk/itm/141767984912?_trksid=p20...

The end looks like it could make a bit of drag and would be better curved bit the principal is okay.

[Mr2Mike]

Twin pass intercoolers inevitably suffer a greater pressure drop than single pass ones of the same size. Generally to be avoided unless no other solution is practical.

[Liquid Knight]

Mr2Mike said:

Twin pass intercoolers inevitably suffer a greater pressure drop than single pass ones of the same size. Generally to be avoided unless no other solution is practical.

That's what I was thinking but more than happy to consult a few oracles.

[Evoluzione]

The cooler you linked to is specifically lambasted and the reasons why it's no good spelled out in simple terms in the article I pointed out to you.



Or read.