Home Brew Intercooler

[matt.mcinnes]

http://images.google.ca/imgres?imgu...mp&start=60&gbv=2&ndsp=20&svnum=10&hl=en&sa=N


One of the reasons I like bosch also is they offer a 24volt pump.

What do you think the weight is going to be including coolant?


Not sure if this will work, never added a link before.

Thanks for the link works fine, I have a few friends that work at Bocsh so I maybe able to get it much cheaper if it's available.

Final weight I have no idea but once finished I can weigh it up, though weight is not a great issue over sturdy construction for competition.

 

[matt.mcinnes]

Dropped the sleeves, end plates and divider in to the welders today. Cash job The guy that does the welding is top notch with a tig. But as a job on the side I have to be patient, 2 weeks.

While this is done all the end caps can be machined up, once we get the newly welded up section back the holes to mount the end caps can then be drilled in the end plates before the final outer skin os welded over.

 

[cheeckyboy31]

i have a hzj75 ute and i am going to mount my cooler core in the centre of the bullbar, horizontally. open the flat bit and put mesh above core or maybe flute the top of the bar to direct air in, thermo also underneath...out of harms way

 

[matt.mcinnes]

All welded up thanks to Awill4x4 and as always top quality work.

Now on with the end caps

 

[matt.mcinnes]

End caps are complete

3/4 assembled

Pressure tested and all good

Next the outer skin is to be welded on, along with the inlet and outlet.

 

[matt.mcinnes]

All ready to weld now

 

[crushers]

pretty damn cool if you ask me...
thanks for posting...

 

[matt.mcinnes]

Will be dropping it at the welders next Wednesday morning

 

[crushers]

looking forward to the fitment...
cheers

 

[matt.mcinnes]

All welded up, just have to drill and tap for the air temp sensor and re fit the intercooler cores. Top notch work too

Once the new engine is ready I have to work out the mounting points and then one last trip to the welders to have them added. This will be early next Jan 08 then plumb it in.

 

[matt.mcinnes]

Well after a night on test for the water not a leak to be found after final assembly.

Each end cap is now sealed with an O ring and Loctite 515 flange sealant which is what the inner grove was machined in for in the end cap, the smaller outer grove that can be seen was just to mark the distance for drilling to mounting holes.

I also dropped it in to have the air flow tested today just out of curiosity results will be in tomorrow.

 

[matt.mcinnes]

Well the verdict is in.

Flow of an unrestricted inlet 65mm/2.5"(straight tube) 400CFM

Flow through my inlet and intercooler 390CFM 65mm/2.5"

Pressure drop 2% under vacuum, this I'm told will be less under positive pressure.

Now not understanding too much about this stuff I asked for an lay mans explanation

The reply was it flows as well as a ported and polished big block and has one of the lowest pressure drops he has ever seen in an intercooler

 

[Dougal]

Flow figures are good.
But too low drag in an intercooler means you may not have enough turbulence for good heat transfer.

Hurry up with the real testing.

 

[matt.mcinnes]

ll

Flow figures are good.
But too low drag in an intercooler means you may not have enough turbulence for good heat transfer.

Hurry up with the real testing.

Testing will be early next year :whoops:

All the air has to pass between a 0.3mm gap over a huge surface area of 1 of 4 heat exchanger fins that are only 0.2mm thick, but I agree until in place and tested it remains an unknown quantity. But so far so good the low pressure drop means not having to run higher boost to have the same pressure at the inlet manifold, not having to run higher boost means generating less heat compressing the air, less heat, less to cool.

http://www.opcon.se/www/files/laminova/pdf/1Intercool_21apr.pdf

 

[matt.mcinnes]

Air Temp Sensor fitted

 

[Dougal]

This job just keeps getting better.

 

[matt.mcinnes]

This job just keeps getting better.

Going to take a punt and say it will freeze Eskimos nipples

That's my $10

 

[matt.mcinnes]

Cores Close up

 

[matt.mcinnes]

Some of this is worth a read. They quoted me $3000 for a custom intercooler to suit my needs, hence this thread started

http://www.hi-flow.com/HPIC3.HTM

http://www.hi-flow.com/HPIC2.HTM

 

[Dougal]

Some of this is worth a read. They quoted me $3000 for a custom intercooler to suit my needs, hence this thread started

http://www.hi-flow.com/HPIC3.HTM

http://www.hi-flow.com/HPIC2.HTM

I've seen pictures of these for about a couple of years now. But yours is the first time I've seen someone actually make one.

I think you need to revise the title. Homebrew to me conjours up visions of almost undrinkable, foul smelling liquid. Not the piece of artwork you've got there.
$3k is about what an aluminium fab shop would need to charge for such a thing.