how to make an intercooler air/liquid
Thread Starter
Joined: Nov 2001
Posts: 7,903
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From: Cleveland, OH
how to make an intercooler air/liquid After some reading, i am thinking about trying to make my turbotech air/air intercooler air/liquid. It doesnt seem to be that complicated. Just weld a "cover" over the exposed fins and add some taps for the in/out water lines. Is it that simple? One article suggested some baffles to make sure water flows throughout the core. Not exactly sure how to do that so i'm looking for some feedback. I think the current intercooler could be moved in front of the hood latch....staying pretty close to where it is without obstructing airflow to the radiator. This project would be much cheaper for me than a new/custom intercooler.
Re: how to make an intercooler air/liquid That is not a bad idea. How good are you at welding aluminum? I think the Spearco Air/water intercooler core is only 3 to 4 inch wide, but they are deeper. That way the water only has to flow in a 4-inch wide area. Also I think the core has thicker walls on the tubing. If the air/air core uses a thinner core tubing, it might be crushed by the water pressure. I would ask Spearco if there is a difference in contruction on their air/air and air/liquid intercoolers
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Re: how to make an intercooler air/liquid Water pressure? It's just recirculated water from a resevoir tank. If there's pressure it's measured in "H2O (tiny).
The A/A requires much more surface area to cool the intake charge than the A/W. That's why the Vortecs and L I/Cs are relatively small compared to the A/As you typically see.
It's kind of rocket science to calculate the SA requirements. Even the Ford boys WAY over engineered their system for safety. The L guys will give you a bunch of supposed "facts" about how this was done for the "Big Mod" crowd, but one look at the warranty terms will tell you that's just not so. The engineering staff at Ford just overcompensated for safety and warranty claims avoidance. The latter being something at which they now accel since the '99 Slowbra fiasco.
Anywho, I wouldn't just suppose that a welded cover on an A/A would be the route to travel, but if you insist, I'd be interested in the before and after IATs...
I wish you well, young apprentice. <img border="0" title="" alt="[Wink]" src="gr_images/icons/wink.gif" />
S-
<small>[ September 27, 2002, 02:32 PM: Message edited by: SS00Blue ]</small>
The A/A requires much more surface area to cool the intake charge than the A/W. That's why the Vortecs and L I/Cs are relatively small compared to the A/As you typically see.
It's kind of rocket science to calculate the SA requirements. Even the Ford boys WAY over engineered their system for safety. The L guys will give you a bunch of supposed "facts" about how this was done for the "Big Mod" crowd, but one look at the warranty terms will tell you that's just not so. The engineering staff at Ford just overcompensated for safety and warranty claims avoidance. The latter being something at which they now accel since the '99 Slowbra fiasco.
Anywho, I wouldn't just suppose that a welded cover on an A/A would be the route to travel, but if you insist, I'd be interested in the before and after IATs...
I wish you well, young apprentice. <img border="0" title="" alt="[Wink]" src="gr_images/icons/wink.gif" />
S-
<small>[ September 27, 2002, 02:32 PM: Message edited by: SS00Blue ]</small>
Re: how to make an intercooler air/liquid If you did put on a cover for the water, it would be good to have it behind the intercooler so the intercooler still gets air.
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Re: how to make an intercooler air/liquid I was thinking of something like this before, but I was thinking of a air to half air half water intercooler mounted in the same place. Then get a crowl pin on hood custom made with a scoop in front of the crowl kind of like the WRX scoop but better looking for an air/water heat exchanger. The air/ air-water would be just as big or slightly larger then our current intercooler.
I'd say the air-water part could take up the first third of the FMIC and the air-air part could take up the last 2/3 of it.
What do you guys think?
There would still be air/air intercooling for backup (good for the street) and there would be air/water intercooling for efficiency.
I'd say the air-water part could take up the first third of the FMIC and the air-air part could take up the last 2/3 of it.
What do you guys think?
There would still be air/air intercooling for backup (good for the street) and there would be air/water intercooling for efficiency.
Thread Starter
Joined: Nov 2001
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From: Cleveland, OH
Re: how to make an intercooler air/liquid I'm gonna try alky too. I found out tonight that my IATs went from 86-169 during a run.....not very good at all. I also found out that I need to get another pump now. My single walbro will keep up on a 1 gear pull on a dyno but it wont keep up thru 4 gears at the track. No wonder this thing has been laying down at the track....I watched the fp gauge tonight......it was back down around 62psi when it should have been at 71-72psi <img border="0" title="" alt="[Sad]" src="gr_sad.gif" />
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TECH Fanatic
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From: SW Florida
Re: how to make an intercooler air/liquid Liquid / Air intercoolers have been around for the Turbo Buicks for a great many years. In fact, Applied Technology & Reasearch (ATR) is still selling them.
Big problem with them; If you fill the intercooler with ice water, they cool the intake charge really well for those 1/4 mile blasts.
However, they ain't worth a **** for a daily driver. The water just gets to hot over an extended period of time!
Keep with your Air / Air intercooler unless your car is a trailored race car.....
BTW, I think the first "vehicle" to run a system like that was the F-111A. This fighter/bomber was developed in the late 60s and used a "Liquid to Air Heat Exchanger" to cool the last stage bleed air from the engines compressor section for its A/C system. To keep corrosion under control in the heat exchanger (water cooler), it used de-ionized water and metal electrodes to prevent metal corrosion within the cooler tank.
Anyway, forget about Liquid / Air intercooling on your daily driver.... <img border="0" title="" alt="[Smile]" src="gr_stretch.gif" />
Ron,
ex-member, 430th Tactical Fighter Squadron, Nellis AFB, NV
"First F-111 squadron in the Air Force", 69-71
_____________________________________________
<small>[ September 27, 2002, 11:06 PM: Message edited by: Kimchee and Rice ]</small>
Big problem with them; If you fill the intercooler with ice water, they cool the intake charge really well for those 1/4 mile blasts.
However, they ain't worth a **** for a daily driver. The water just gets to hot over an extended period of time!
Keep with your Air / Air intercooler unless your car is a trailored race car.....
BTW, I think the first "vehicle" to run a system like that was the F-111A. This fighter/bomber was developed in the late 60s and used a "Liquid to Air Heat Exchanger" to cool the last stage bleed air from the engines compressor section for its A/C system. To keep corrosion under control in the heat exchanger (water cooler), it used de-ionized water and metal electrodes to prevent metal corrosion within the cooler tank.
Anyway, forget about Liquid / Air intercooling on your daily driver.... <img border="0" title="" alt="[Smile]" src="gr_stretch.gif" />
Ron,
ex-member, 430th Tactical Fighter Squadron, Nellis AFB, NV
"First F-111 squadron in the Air Force", 69-71
_____________________________________________
<small>[ September 27, 2002, 11:06 PM: Message edited by: Kimchee and Rice ]</small>
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Joined: Jun 2002
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From: Georgia
Re: how to make an intercooler air/liquid Dunno Cablebandit sure sounds feasible but my cooler is air/water but as said before it is a S/C not a Turbo. But I haven't been messing with these things long enough. I'd like to help you anyway. How did she run tonight by the way.
PM me when you can George and I would like some help next weekend if you don't mind, Autotap kind <img border="0" title="" alt="[Big Grin]" src="gr_grin.gif" />
PM me when you can George and I would like some help next weekend if you don't mind, Autotap kind <img border="0" title="" alt="[Big Grin]" src="gr_grin.gif" />
Thread Starter
Joined: Nov 2001
Posts: 7,903
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From: Cleveland, OH
Re: how to make an intercooler air/liquid Ran like crap, outta fuel pump. My favorite run was...stage...let car next to me go...roll out 20'....mat it! 13.7 @ 121mph on a 2.7 60'...I need another fuel pump intank and a torq arm.
Re: how to make an intercooler air/liquid Id do the sump and big aeromotive, reckless here has done it and he says it gives him plenty of fuel. Even Harlan was switched to it. Im going to as funds allow.
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Joined: Nov 2001
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From: san diego ca
Re: how to make an intercooler air/liquid how about something even cheaper and easier -
AN AUTOMOTIVE HEATER!
think about it - you run hot water in to heat up an air stream
who says you can't run it backwards; run in cool water to cool off an airstream
heaters are a dime a dozen at a junkyard - it wouldn't cost much to try the experiment; just get the biggest one you can find for maximum airflow <img border="0" alt="[Fluffy]" title="" src="graemlins/fluffy.gif" />
AN AUTOMOTIVE HEATER!
think about it - you run hot water in to heat up an air stream
who says you can't run it backwards; run in cool water to cool off an airstream
heaters are a dime a dozen at a junkyard - it wouldn't cost much to try the experiment; just get the biggest one you can find for maximum airflow <img border="0" alt="[Fluffy]" title="" src="graemlins/fluffy.gif" />
Thread Starter
Joined: Nov 2001
Posts: 7,903
Likes: 1
From: Cleveland, OH
Re: how to make an intercooler air/liquid I cant afford a new fuel system. I'll have the second walbro intank tonight/morning. I now can see my intercooler sux so no reason not to try to convert it to air/water and see how it goes. Harlan said his IATs were 20* over ambient with the incon intercoolers.
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Joined: Nov 2001
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From: Bellevue, Wa
Re: how to make an intercooler air/liquid cable, try the water/alky
your iat's will end up at or below ambient and the alky acts as more fuel/octane.
it would be perfect for your setup.
I have run 5 gallons of water/alky thru my motor thus far. works perfectly.
your iat's will end up at or below ambient and the alky acts as more fuel/octane.
it would be perfect for your setup.
I have run 5 gallons of water/alky thru my motor thus far. works perfectly.
