intercooler design?

XFlow_Fairlane

XFlow_Fairlane

2K+
VIP
http://img.photobucket.com/albums/v701/ ... cooler.jpg

this is what I am thinking of an intercooler setup in my car. I have one saab 900 core sitting here (cut/pryed the plastic tanks off tonight) and am getting an all AL one later this week from a buddy. these cores with the outlets off the AL tanks will give me the hard parts and just will need to pick up some flat stock for the rest. the middle "tank" is like that to clear the grill, headerpanel, stone deflector support bar (also hood saftey catch) in that drawing it is 1.75" thick on the inside. the cores measure 2.5" x 8.75" on the ends and are 8" long each. so what do the hardcore experts think? (btw I will have under $100 in the whole intercooler)

the tanks will be a little more conducive to flow and the whole unit a little wider but I just cranked this out in a a few minutes to get teh size and shape down a little better.
 
Skinnyllama????

That is just another one of those crappy automated search engines that takes you to eBay auctions!!

I got mine from xoxo racing, I think.
 
ever did thought about a water intercooler ? intregated into an aluminium cooler ?
 
I saw about 3 pages and got too wrapped up to check it all the way out. It is all ebay, all 50 pages of it. What in the hell is that all about? Just Googled Intercooler and it was an option. I was suprised to see the tubing kit's and ell's. One of the I/C's caught my attention for a $130 price tag and I remembered this thread.
 
well a genaric fit IC prob isn't going ot work too well with my car since there isn't alot of realestate in the front end where it can get goood airflow. I had thought of a water-air setup but then I need to run a pump and for driving in traffic in summer weather it would become useless REAL fast. generally water coolers are for drag cars only. having the heatexchanger integrated into the radaitor is a bad idea. a company did it for the tbird's and svo's that was an air/air on top of a ratiator and it had bad heatsoak with it. I would think that you would be picking up more heat then you would be getting rid off on them being integrated. I wish I could get it but there is a pair of old griffon radaitors in teh formula SAE shop that would be perfect for it. about 18" wide 2.5" thick and 12" tall...but I think they would miss one real fast. but then I am back to messing with pumps and a tank and all....far too much work I think.
 
You can always go side mount instead of front mount.

In air-to-liquid intercoolers, the pump only circulates when making boost (or manually, like on the starting line)

griffin radiators would not flow enough. OK for liquid flow, bad for airflow.
 
well the griffon would be for the heat exhanger in a air-water setup.....use a jacketed intercooler and the griffon with a tank and transfer pump
 
I saw a guy with a nice TT 302 Fox stang, he had it mounted parallel to the ground. Sucker was stock, 11's. Nice idea for an IC, better great flow, but debris would be my only qualm. Pop it and some serious issues arise.
 
I haven't recieved my books yet, but is there a magig formula for sizing the I/C and pressure tubing?

I think a lot of us have the same mounting issues, and then you have to deal with plumbing. If you're like me aesthetics are important, so it has to look right when it's done.

I've got a guy nearby that custom builds alum radiators. He said he had built some intercoolers. I am going to get some dim's off the Mustang and see what he can do. I have no idea what his approach will be for tanks, in/outlets, surface area, etc. Any tips will help, and if he is reasonable I'll post. I have seen his work and it is outstanding. His custom app's are comparable pricewise to "BeCool" products.
 
well the only formula I know of is "take how much room you have - how much room you need leftover = how big of an intercooler" basicly the biggest you can fit on air-air ic's the key thing is trying to keep a large cross sectional area as this reduces the pressure drop.
 
Howard":93ospetc said:
I am going to get some dim's off the Mustang ..... Any tips will help, .
Click to expand...

post the dimensions here and I'll make a recommendation.
 
im gonna strongly recommend against the design in the link at the top. Its just begging for pressure drop. You want to move across the shortest side of the core with your air charge, typically with a 2-3 small core setup, you want to line both cores up and fab a long tank on either side with a baffle in each splitting the cores. Its really hard to explain why, (see the maximum boost book for details)
I highly recommend air to water. Aluminum xfers 14x more heat when contacting water as opposed to air alone.
 
AtroXR7":d87dlbw2 said:
im gonna strongly recommend against the design in the link at the top. Its just begging for pressure drop.
Click to expand...

It will be fine for the airflow demands needed AS LONG AS there is enough airflow designed into the dimensions so pressure drop won't be as large a factor....

The final dimensions (and core type/construction)
would be needed to perform any initial assumptions.
 
the core sizes are posted above (cross sectino measures 2.5"x8.5" and are 8" long. I would mount them side by side but there is not enough room for them there......well not withough cutting up THE WHOLE front of the cars sheetmetal.

well anyway I bought this second core without looking at the two together and it is the other style of SAAB core....same size but different tube style GRRR

so off to find a third core.....

I was tempted to jacket the one I had bought and run air/water.
 
My bad for not looking!!


turbo_fairlane_200":2r0nbtpe said:
the core sizes ,,, 2.5"x8.5" and are 8" long.
Click to expand...

2.5" x 8" with a bar and plate design would get you to around 200-250 HP but since those are "tube and fin" design, you would need to split the flow so you feed both cores at the same time, instead of flowing from one into the other (parallell versus series)

otherwise you will probably have too much pressure drop
 
turbo_fairlane_200":18k318vd said:
I was tempted to jacket the one I had bought and run air/water.
Click to expand...

I started on a air to water based on an A/C evaporator core. Much more efficient than converting an air to air over to air to water. I never finished it.
 
yeah basicly all I would need to do is bend up two pans on the brake at school and weld them on....find a couple AL scrap hunks to make some weld bungs for outlets and I would be done....BUT the stock saab 900 IC is a dual pass design (so uses only HALF that cross sectino to pass the air through) so I figured unless I put on new tanks it would be a waste....well except for maybe ebay
 
You must log in or register to reply here.

Similar threads

XFlow_Fairlane
pics to follow....
Replies
2
Views
1K
XFlow_Fairlane
XFlow_Fairlane
B
  • Locked
Idiot's guide to turbocharging the falcon 6
2
Replies
22
Views
29K
AngryEyes
A
B
So how does the 200 really stack up? (long)
2
Replies
25
Views
6K
addo
addo
Back
Top