WAIC - Water/Air Intercooler for TRD SC (1 Viewer)

[FirstToy]

Inverness and I have been working on WAIC systems for our TRD SC 80's.

Rick (Inverness) has gotten further along with his about done. Also he has a great monitoring setup.
I still have to install my sensors/gauges but will update when I do.

Function:
The purpose is to cool down the compressed intake air. The concern of overheating with SC led down this path.
with cooler air, you can also use a smaller pulley to up the boost.

The reason WAIC instead of air-to-air FMIC:
*superior cooling at trail/crawling speeds where A/A IC is not effective
*less pressure drop
*superior heat transfer of water

There has been a lot done in the turbodiesel applications (I also considered Laminova WAIC's but expense and fabrication was overboard for what the TRD SC puts out.)

diagram of the system layout
(note: changed flow path thru IC radiator routed from bottom to top to minimize air bubbles)

 

[FirstToy]

fabrication
shiney WAIC's

precision cutting with a phat hole saw and Rick's cool, magnetic portable drill press

fitting up the 90° angle

test fitting on Rick's truck
since the IC is in-line, this is a direct line to the intake with no pressure drop from extend lengths of convoluted piping

in progress- a good photo of some of the major elements in the system.
If you look carefully, the 12V fan can double as a Cuisinart: the finger chopper!

Rick heavily modified the IC radiator to fit by welding new inlet/outlet pipes as well as mounting tabs, etc

The IC radiator fits behind the grille w/ a 12V pusher fan. This side now draws in much more air than the other side.
I believe it has increased the airflow into the engine radiator despite adding another radiator

The system automatically turns on w/ the ignition.
I have a switch to turn off the 12v fan & IC pump independently, for maint or deep water, etc.
so I tucked the switch away here, unlikely to get touched unless needed.

 

[FirstToy]

Gauge
Glowshift 3 in 1
*modified to be 4 in 1

reads BOOST, IAT POST-IC, EGT, TRANS

*backlight can change to 10 different colors- will use green to match

The switch toggles between IAT and TRANS temps

pump on/off

downside is that this is a diesel gauge so the boost will show very little
however, I chose it because I can get 4 readouts in one unit.
*note: this is not a good gauge to use because it the boost blinks w/ vaccum. It is not in any of their tech specs so that is disappointing.
If I had a diesel, it would be a nice bonus. As it is, a bit annoying although it doesn't bother me as it's not 'in my face'.

Sheldon's vent gauge setup is the slickest mounting but with all I had to do with this project, just didn't have the motivation to tear apart the dash.
The pillar pod was simple and it does make wiring very easy.

I will try to get Rick's computer setup pics later

 

[calfj60]

Sounds interesting... Subscribed..

 

[Romer]

Cant wait to see the progress and results.

 

[sandcruiser]

very interesting
eventually, I would like to put together a WAIC that also has some A/A with a hood scoop... on my hd-t
eventually might be never, but I'll be watching your waic because it looks like it is in more or less the right spot for what I would want to do.

 

[landtank]

very nice stuff. The SCs have needed something like this for a while.

 

[akarilo]

Nice bit of fabbin.

 

[Tapage]

the aditional rad catch my eye .. maybe I can mount in the other side of the rad and add my PS oil cooler on front .. where do you get it . ?

 

[pr0ject42]

Are you going to put a smaller pulley on there now?

 

[rockclmbr]

Nice fab work guys!

Hope it works out.

 

[TX Cruiser]

Looks nice and should help. That's not an inter-cooler though. It's an external charged air cooler.

 

[sandcruiser]

From Miriam-Webster:
Main Entry: in·ter·cool·er Pronunciation: \ˌin-tər-ˈkü-lər\
Function: noun Date: 1899

: a device for cooling a fluid (as air) between successive heat-generating processes

 

[FirstToy]

Rick has been monitoring his temps and has some good results with the WAIC.
I will snap some pics next time I see him or he might post up.
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I have a PWR IC radiator and Rick has a Frozenboost radiator
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I have no plans to add a smaller pulley to up the boost. Maybe later.
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all forced induction air cooling systems are technically "charged air coolers".

I have heard location determines if it's an "intercooler" or "aftercooler".
turbo-->IC-->turbo-->IC-->intake = intercooler
turbo-->IC-->intake = aftercooler

also heard that A/A = intercooled, AW= aftercooled.
I don't know which is correct but everyone knows it as "intercooler"

Factory WAIC's and FMIC's, TMIC's are all designated "intercoolers".
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I have also found it helpful to think of them as "heat exchangers" instead of radiators.
It made me think of the entire cooling system as it really operates and not based on assumption.

 

[clownmidget]

James, why is Rick's air filter housing flat tan in color/appearance? I noticed you had yours wrapped/plated in reflective gold - I guess to reduce heat absorbing into the intake air? But the tan looks old skool kool

 

[FirstToy]

that's cake frosting!

actually it's some kind of paste ceramic coat.
yeah both are for deflecting heat from the intake

 

[PabloVTA]

baked Alaskan..... subscribed!

 

[AMMO]

Dam Boys.... PIMP.... James you have come along way from the bubble emblems...

Nice guys, very nice.

 

[landtank]

One thing that I will be looking into is using the "alt good" signal to operate the pump automatically. I think it's a 12v line that goes to one of the fuse blocks and can easily be tapped into for this purpose. That way the pump is only running while there is alt output which would mean the engine is running.

Just a thought

 

[FirstToy]

thanks Matt, it's nice to work with someone as knowledgeable (with a nice shop!) as Inverness.
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fuse block in the engine bay?
I have it tapped to the ign fuse under the dashboard. system turns on automatically with the key.