Home Brew Intercooler

[Dougal]

BTW: Dougal, I like your sig. A friend of mine is a civil engineer working on a hydro dam right now. He loves it (for the most part).

Thanks. I stole it from an engineer on another site.
I'm mechanical type, have done some hydro-electric work and considering going back to it.

 

[matt.mcinnes]

Well from my drawing Dave good friend and Navi came up with this and it's in one piece. Just need to sort a radiator out now with a thermo fan 12" I think, so we have the size for the piping.

My excuse is I don't have CAD on my Mac

We also elected to cool the Turbo from the slightly warmer engine cooling system rather than the chilly intercooler.

 

[matt.mcinnes]

Spent the evening calculating Turbo outlet temps for the Garrett GT3082R @ 70F/21C ambient and from what I can work out at 9psi the outlet temp should be around 180F/82C at 15psi the outlet temp rises to 227F/108C.

Now if the intercooler is as good as I hope we should be looking at some good results.

If I have done my math right and built an intercooler that works.


Calcs using this.

http://www.gnttype.org/techarea/turbo/turboflow.html

 

[Dougal]

Spent the evening calculating Turbo outlet temps for the Garrett GT3082R @ 70F/21C ambient and from what I can work out at 9psi the outlet temp should be around 180F/82C at 15psi the outlet temp rises to 227F/108C.

Now if the intercooler is as good as I hope we should be looking at some good results.

If I have done my math right and built a intercooler that works.


Calcs using this.

http://www.gnttype.org/techarea/turbo/turboflow.html

For 70% efficiency my spreadsheet brings out almost the same numbers (81 and 113 deg C).

Can't wait for the intercooler outlet temp measurements.

 

[nickw]

My excuse is I don't have CAD on my Mac

We also elected to cool the Turbo from the slightly warmer engine cooling system rather than the chilly intercooler.

I am a mac user too (since about 94). Use them at work all day. You could run any windows app you want via parrells, and coherance. Fits right in. But you might not want to. Or you could go the "old fashion" way with bootcamp.

Also, it makes good sense to leave the turbo on engine coolant lines. I was wondering if the intercooler system could keep the water cool, as well as the turbo. Not to mention the cracking issues.

Cheers,
N.

 

[nickw]

Hey Matt,

Any updates on the intercooler?

Cheers,
N.

 

[matt.mcinnes]

All quite now until it's fitted, will make the water splitter up over Xmas.
New engine should arrive 21st Dec. Will also source a radiator and Thermo fan.

So all I can say is watch this space in 2008.


Until then Merry Xmas and a HAPPY NEW YEAR

 

[matt.mcinnes]

Ok getting there, engine was delayed but sometime next week should see it fitted. Then onto fitting the intercooler and Turbo Manifold and all the pipe work.

But for now the mountings are sorted, just need to get Awill4x4 to weld them on. So we have something like this.

 

[Dougal]

But for now the mountings are sorted, just need to get Awill4x4 to weld them on. So we have something like this.

Uh-huh, that makes sense. Awill4x4 has some nice stuff showing on outerlimits at the moment too.

 

[matt.mcinnes]

Uh-huh, that makes sense. Awill4x4 has some nice stuff showing on outerlimits at the moment too.

His welding is second to none the guy is a genius.

I would not take my welding any where else.

 

[awill4x4]

His welding is second to none the guy is a genius.
I would not take my welding any where else.

Aw shucks Matt you're making me blush.
I've just welded up a big Garrett 4.5" thick cored air to air going on a big horsepower RB30 engined Commodore and that came up very nice too.
Regards Andrew.

 

[matt.mcinnes]

Well DJB excelled himself again, My sliders, rock, my wide mouth winch, rocks and now the 4 way splitters for the water supply to the intercooler are space age

Also some interesting reading for Laminova all be it in a Mazda MX5

http://www.kennebell.net/techinfo/mazda/miata-dyno-results.pdf

 

[matt.mcinnes]

Intercooler is mounted just the pipe work to complete.

 

[matt.mcinnes]

Done, just need to swap the water fittings to 90 degree ones.

Now for cooling the intercooler.

 

[Tapage]

Looking pretty clean .. congrats dude .. very impresive job.

 

[Dougal]

Looks great.
But that corrugated hose from the intercooler to the throttlebody, is that needed for movement of parts?
A smooth hose would give a lot less turbulence to the flow.

 

[matt.mcinnes]

Looks great.
But that corrugated hose from the intercooler to the throttlebody, is that needed for movement of parts?
A smooth hose would give a lot less turbulence to the flow.

The hose is just for set up awaiting one with a custom bend in smooth silicon.

 

[matt.mcinnes]

Wiring for the air temp sensor is done Monday will see me pick up the 90 degree hose tail water fittings water fittings.

Then all I need to do is mount the radiator, water pump and connect the lines.

Dyno is booked for the 19th May

 

[_Mitcho_]

hey matt

that motor is awesome, well done!!

 

[matt.mcinnes]

Looks great.
But that corrugated hose from the intercooler to the throttlebody, is that needed for movement of parts?
A smooth hose would give a lot less turbulence to the flow.

I guess 99% isn't good enough for some folks, I will say NICE FRICKEN job!!!!!!! Awesome install!!!!!
eric

Dougal is right, as of today it looks like this.