Water-Air custom intercooler build

[jbpace]

With my supercharged engine essentially rebuilt (even if the tranny isn't bolted up yet) I'm ordering materials to build my Water-Air intercooler.

The base of the project is (3) Laminova 39.5 x 392mm cores I sourced off ebay:

Tonight I ordered all the 6061/6063 aluminum plate/flat/tube. Used SpeedyMetals.com since I've had good experience with them in the past.


I'm now researching parts for the heat exchanger, tubing, etc. and found a place called FrozenBoost.com. Looks like a good outfit, but I've never used them and was hoping someone on the forum has had past experience - anyone??

They have two parts (that form a functional unit) that I'm particularly interested in. The first is a set of pipe ends I'd use to connect the intercooler to the intake manifold:

the second is the clamp that holds them together:

My vision is to mount the intercooler over the head, between the supercharger outlet and the intake chamber. These give me a quick release on the intake end to remove it for completely open access [unfortunately I think I'm stuck with bolts on the other end]. Does that sound reasonable? I know it's not terribly clear, but will hopefully make sense as I add build photos.

Be advised, this project is NOT going to move quickly. I still need to buy a TIG welder, but just learned tonight I owe even more $$ to the IRS. I'll update as I move along, I'm just terribly busy & underfunded.

Thanks for the advice,
Jon

 

[FJFOOL]

Looking forward to the build, Jon. Thanks for posting it up !

 

[Delancy]

Bump...

 

[scottryana]

The luminova cores are great, the frozen boost heat exchanger wouldn't do them justice. Frozen boost is who I got my "600hp" intercooler from that couldn't handle 400hp.

 

[Delancy]

Have spent too long on one of our own's threads on a Patrol forum, checking out the Luminova core options.

All I gotta say is, this better prompt as many brownie points with Toyoda as the Redheaded 2F+....lotta work to keep it all OE...

 

[BOOSTED80]

I would like to switch to a laminova cooler from my cheap frozen boost cooler..although i cant complain it has dropped my iat about 80 degrees C.
Look forward to some updates.

 

[scottryana]

It dropped it 80c or to 80c?? That's still very high

 

[murf]

Its been a year and a half since first OP post...

He warned it could be a slow build!

 

[BOOSTED80]

@ scottyryana , it dropped it around 80 degrees C on a hot day with about 35 degree ambient temps cruising down the highway with no cooler i was seeing 115 degree iat .
After i put the cooler on doing the same driving i would see 36 degree temps.
After having it on for a while now i am usually seeing about the same iat's as the ambient air temperature..within a few degrees

 

[scottryana]

At 115c/239f cruising down the highway! Under boost weren't you having bad detonation issues? That's great that you were able to see such a big drop! my role of thumb is generally if you can see 170f you need a bigger/better IC.

 

[maxamillion2345]

How are you guys measuring IAT?

If I had a dyno I could temp gun mine but otherwise??? Install temp probe and gauge?

My EGTs are stupid high (like 1000-1100 degrees going 75 on flat ground) and my crappy little frozen boost setup seems to be helping very little if at all, but that's only based on runs with the fan and pump off and then again on and comparing EGTs.

I'm wanting to see exactly what it's doing.

Thinking of an air to air top mount with a hood scoop? Maybe a bigger air to water?

I have their 350 hp kit right now.

 

[scottryana]

Yes you need to install a temp sensor probe after the IC. I have the 600hp IC from them and it doesn't do a lot. I posted graphs of my intake temp and how quickly it spikes. After an attempt to fit a much bigger and better core failed when the fabricator made the new IC too large, that's when I went to water/meth injection.

In the back of my head even if you just went to a better core that is the exact same size I know it would work better. At some point I would like to just send Bell Intercoolers the dimensions and have them build one. But like you have seen the frozen boost is marginal.

 

[maxamillion2345]

Yeah sigh, it's only money right?

 

[scottryana]

Yeah, but you know that old saying "buy once cry once".

I spent a whole lot more money effing around with this than just ponying up the 5-6x more that a really good intercooler would have been over that frozenboost junk.

Yeah sigh, it's only money right?

 

[maxamillion2345]

It's just a nightmare trying to figure it all out. I'm going to see what a better turbo will do for me, I have one it's just going to take some work to get it all bolted in, and then I have a small water meth setup I'll install and maybe between the two of them I can get my EGTs manageable. Seems easier than throwing money at the IC setup to see what works. I'd like to gut that stupid frozen boost setup entirely but I think it is helping a little...

I'll bypass it and go for a drive and see what my EGTs do I guess.

 

[ppc]

My EGTs are stupid high (like 1000-1100 degrees going 75 on flat ground) and my crappy little frozen boost setup seems to be helping very little if at all, but that's only based on runs with the fan and pump off and then again on and comparing EGTs.

EGTs of 1000 F to 1100 F degrees are actually quite normal for a NA 1FZFE uder the conditions you describe. Cruising at 75 on flat ground a superchared engine is producing little or no boost. Under full boost and significant load 1500 F may be more typical. I would not be overly concerned unless that is exceeded or that is reached for long periods of time.

 

[maxamillion2345]

I appreciate the help but I'm actually running a 5.9 Cummins diesel.

Sorry for the confusion.

 

[maxamillion2345]

Bypassed the frozen boost, straight from turbo to intake, same hill same ambient temps same speed same EGTs.

I can't say 100% in all cases but it sure seems like when pulling that hill at 18 lbs of boost that intercooler did absolutely nothing.

I am going to get rid of it and work on installing a better turbo and my water met set up.

 

[Arabian Cruiser]

With my supercharged engine essentially rebuilt (even if the tranny isn't bolted up yet) I'm ordering materials to build my Water-Air intercooler.

The base of the project is (3) Laminova 39.5 x 392mm cores I sourced off ebay:

Tonight I ordered all the 6061/6063 aluminum plate/flat/tube. Used SpeedyMetals.com since I've had good experience with them in the past.


I'm now researching parts for the heat exchanger, tubing, etc. and found a place called FrozenBoost.com. Looks like a good outfit, but I've never used them and was hoping someone on the forum has had past experience - anyone??

They have two parts (that form a functional unit) that I'm particularly interested in. The first is a set of pipe ends I'd use to connect the intercooler to the intake manifold:

the second is the clamp that holds them together:

My vision is to mount the intercooler over the head, between the supercharger outlet and the intake chamber. These give me a quick release on the intake end to remove it for completely open access [unfortunately I think I'm stuck with bolts on the other end]. Does that sound reasonable? I know it's not terribly clear, but will hopefully make sense as I add build photos.

Be advised, this project is NOT going to move quickly. I still need to buy a TIG welder, but just learned tonight I owe even more $$ to the IRS. I'll update as I move along, I'm just terribly busy & underfunded.

Thanks for the advice,
Jon

Hi Jon,

Hope all is well.

if you are still on this earth and not behind bars give us an update if any on this project. Want to do the same thing.

thanks

 

[jbpace]

Hi Jon, if you are still on this earth and not behind bars give us an update if any on this project. Want to do the same thing.

Amazing - I haven't been on 'Mud in years, come in today (because my son's LC seat got stuck) and see your post. Unreal...

My project has unfortunately been on hold for years. The engine is rebuilt, but the intercooler frame and tubes are only tack-welded because I haven't made time to locate a TIG professional. Both our kids are currently in college, so I'm working a lot to pay the bills so they get out debt free (cross fingers).

I completed the design, and had the endplates CNC milled. Because I'm paying one-off prices, I think I've already spent >1,600 US$. If anyone is interested, I can try to find the files I uploaded. I'm sure I have the CAD files, if you can use (or import) Rhino .3dm files.

I'll watch the thread so I get an email this time.