My Turbo Intercooler Setup

[Tapage]

Intercooler Discharge Temperature

You are running 12 PSI of boost with an ambient temperature of 86 degrees F. Your Intercooler has an efficiency of 70 %. At this boost level the temperature of the compressed air reaches 186.46 degrees farenheit at the turbo nozzle, and 116.14 degrees farenheit exiting the intercooler.

http://www.actionspeedparts.com/intercooler.php

Little calculation for my setup .. here in Panamá

 

[big80]

I personally wouldnt use ANY JDM factory built cooler on any custom install. They are built with "cost cutting/money saving" in mind. They flow s***e all and cool even less. i would buy a new cooler, the best you can afford, something around the 500mm x 300mm x 76mm (this is the size i have on my 80 series, a PWR item), with 2.5" inlet/outlet. Where the pipe will join into the compressor outlet of the turbo, make sure its a nice long taper from 1.5" (or whatever size the comp. outlet it), out to 2.5" for the piping, otherwise, if you try and put a 2.5" pipe straight out from the turbo, it loses air speed. I wouldnt worry too much about pipe length either. It takes a millisecond for the turbo to pressurize the entire system, the biggest restriction in a intercooler system will always be the cooler itself.

Can i email you pics of the setup i have on my 80 series, or can someone post them up for me?

Phill

 

[Tapage]

The intercooler that a post have a 2 1/4 and 2 1/2 pipes .. it's from a Kia Sportage .. I thought is fine .. about the size and pipes .. are is also fine for hood scoop.

I'm in shoping right now for piping .. and take in mynd my turbo have a 2 1/4 outlet and I'm shoping for 2 1/2 down pipe and one adapter to 3" for finaly exaust pipe ..

 

[crushers]

hummm, i was told to run a larger inlet and a smaller outlet on the intercooler since the volume of air lessens when it cools...

 

[Tapage]

hummm, i was told to run a larger inlet and a smaller outlet on the intercooler since the volume of air lessens when it cools...

Let me see .. smaller outlet means to the intake manifold .. and larger inlet means larger to the turbo ?

 

[andrea-PE-ITALY]

larger inlet means from turbo to intercooler and smaller inlet means from intercooler to engine

 

[crushers]

yep, you both are right...
;^)

 

[Tapage]

Ok this weekend start to figure how to place the intercooler in the top of the engine .. I thought I need buy a hood scoop ( summit ) and take some measurements for my exhaust .. I re think it and will go with 2.5"

 

[dieselcruiserhead]

cool.... My best guess is that intercoolers do not noticably help on a 2H setup which is why none of the aftermarket turbo guys offer intercooled versions. But that is just my guess. Of course these guys have throughly mapped and tested. You can call turboglide in Aus they are very helpful on the phone. One of my favorite intercoolers is the Volvo 240 and 740 gasoline wagon intercoolers. It worked very well with my 4BT, not too small not too big, wide but thin about 1" thick at the fins. Max boost about 25 psi they say, which I hit a few times with no problems. 2.5" ports. Might require some work, you would need to move radiator back I think about 2" overall. Anyway good luck with it tapage, keep us posted with pics..

 

[Entaran]

RE Intercoolers...

If you want a factory item, grab one off either a 88-93 Toyota Supra (looks like the last one you posted) or a 88-92 Mitsubishi Galant VR4 (Japanese version, it looks like an aftermarket cooler). They are the ONLY two factory coolers worth anything (lancer evolution coolers are also good, but are EXTREMELY pricey).

ARE.com.au and PWR.com.au are the only other places i'd consider getting a cooler from as all the "ebay" special coolers generally have massive pressure drops over the core and/or aren't rugged enough in the welds to survive serious offroad abuse. You will also need to fabricate mounts for the cooler and I SUGGEST you put rubber washers between the chassis and the actual mount to absorb at least some of the vibrations.

Silicon hose should be used on either end of the cooler and connected to hardpipes, try to use at least 4 sections of silicon on the entire system, generally around 6. Two for the intercooler, one for the throttlebody one for the compressor outlet. If you have to put an expander on the system (the throttlebody is bigger than the intercooler outlet), then put it as close to the throttlebody as possible as it creates turbulence in the pipes and can cause power loss.

If you use mild steel for the intercooler pipes, have it ceramic or gal dipped otherwise the inside of the pipework will rust and will go into your engine. Don't argue, i've killed a 4g63 (lancer evolution) engine like this. If they're stainless, use extra silicon as stainless can expand as much as 3 full inches with the heat depending on the pipe length and wall thickness. If you use aluminium, make sure the welds are properly done as it has a tendency to possibly leak.

The location you mount your cooler is upto you, you need somewhere that has good airflow. Usual places for Aussie cars is up top with a topmount (generally off a subaru WRX) using a GU patrol bonnet scoop cut through the bonnet and an 8 inch thermo fan under the intercooler to pull air through at low speeds and/or temperature switches against intake temp. This can add up to a lot of money though. Steer clear of water to air setups as in low speed 4x4ing they'll overheat pretty quickly (they're effectively a small radiator without coolant).

Anything else you need to know feel free to PM me.

 

[Tapage]

Dude . thanks for all your commets are highly aprecitaed ..

1. Top mount intercooler, with Hi Lux ( 2006 ) scoop, not sealed to hood and the intercooler atached to engine with bases and rubber vibration aislators.

2. Virtualy no piping needed with the intercooler, O thought as much one solicon hose turbo-intercooler and other intercooler-throtle body.

yesterday I order from summit 2.5 mandrel exaust parts ..

Today I was reciving my boost gauge and 3 gaugue pod

 

[Tapage]

Aja !!!!

 

[JoeCanadian]

Good reading,....... If i read it i dont even need to think.

you guys are talking like 10 - 25 lbs of boost. i was wanting to know if 7 driving at about 2300 - 2500 rpm and 10 - 12 at 3200 rpm on a 3b is a good amount. It feels good, but hom buch boost can a 3b take? the stock 13bt is about 6 - 8 lbs of boost.
and do i need to gook up the waist gate??? the turbo is out od a 2.2L dodge. Brand "Garret" the cartridge is the same as the after market $2700 upgrade. Damn thats big cash for 20 - 30 HP

thanks Les

 

[Tapage]

13B and 3B can handle really easy about 14 lbs of boost ..

 

[crushers]

Mark is running 20 lbs of boost (i beleive) and tippyR is running a gazillion lbs but then these are off road dedicated units. 14 lbs is fine 8-9, depending on the turbo, is adaquate. too much boost with out an intercooler is self defeating anyway (heat generated)
go 14 lbs and add propane injection if you still need more...

 

[Tapage]

Well mates .. after I broke an axle ( rear long one ) last thursday, I loose some time searching in internet and about stock one and cromo replacement ..

here some pics ..

after I check the prices .. I decide swap my SF for a FF axle ..

I found a stock replacement here in Panama .. but definately FF my next step ( jaaaa long road never ends .. )

Well now to intercooler propset place ..

I thought I gonna move the elbow to front and some little piping to get it into throtle body ..

 

[andrea-PE-ITALY]

go on TAPAGE, I stay tuned on your job. ciao

 

[Tapage]

Well guys I'm back again ..

after some weekend dealing with my broken axle, I decide do something with my e-brake cables .. and buy those ones and work on a braket.

proceed to adjust the caliper and re-arm all again ..

with new setup it seems to be more eficient ..

New axle in I take time to adjust my R&P verify bearing and all ..

Las sat start again with properly turbo stuff ...

nice uuhhh !

As I only have sat and sundays to work in my rig, I ask for some help to push some gas in the proyect ..

I pic my adapter on sat from machine shop ..

take some measurements ..

before turbo I place my pyro sender unit in the down pipe .. but now it will be in the manifold, preturbo

Finaly I need to long the wastegate braket to allow it in my engine space ..

Finaly I'm little worried coz my turbo will be fit behind my AC compresor ( still funtion and I love my AC here in Panamá ... coz houe temps .. among others .. ) I'm little owrried about the head in the compresor and I must use a 45º elbow for the turbo intake coz I the compresor ..

More pics .. tomorrow ..

 

[crushers]

sweet,
keep the report coming...
fun read...

 

[Tapage]

More .!

ha .. hey Wayne why you said fun read .. coz I need re-educate .. means back to school . ?

anyway

2.5"

cha cha cha channnn !!!!!

I'm really happy !!!!!!!