How do you *really* determine an intercooler's limits?

[bryson]

I'm wondering this because, well, I'm interested in going back to an air/air setup on my Fiero (*gasp*) -- I want to get rid of my water/air intercooler because the endtank setup isn't going to work well with my new turbo placement. I was going over some options when I found some pictures of my old twin intercooler setup. I had problems with that setup, but they were from leaks that I didn't know that I had, not from the intercoolers or from the amount of piping.

Anyway, I can think of four options for when I do my new setup.

1) Sell my water/air intercooler, and buy one from ebay. The only problem with these are that I would like to have my inlet and outlet on opposite sides.

2) Figure out a way to make different endtanks for my intercooler. I would love to figure out a way to make composite endtanks bolt on, but it doesn't seem too easy. The only thing I can think of is to cut the existing endtanks off, and fold flaps out to create a flange to bolt the composite endtanks to. This would be crazy awesome if I could make it work.

3) Use my old twin intercoolers -- I could even put in a permanent aluminum crossover pipe to minimize connections. This looks the best, but the problem is that my turbo is going to be over the transmission, so the pipes would have to make a 90 from the turbo exit (at best, it will point straight up) and go to the passenger side, then a 90 into the endtank, where it will make another 90 into the core -- then it will go across, make a 90 out of the intercooler and another 90 into the intake manifold. Sounds like a lot of pressure drop. (Each I/C would have a sealed duct to a side scoop, as well as a fan)

4) Use just one air/air Ford Turbo Coupe intercooler in the driver's side decklid vent. Once again, it would be ducted to a side vent, all sealed off, and have a fan under it. This would be slick because the turbo can be clocked to where the compressor outlet shoots straight towards the drivers side, where it would come up into the intercooler, straight through, and back down right into the intake manifold. My only concern with this is that the Turbo Coupe intercooler might not be able to flow as much air as I need, or cool the air as well as my water/air.

What would you guys go with? Twin air/air looks best, single water/air with custom endtanks would probably perform best but be difficult to make (if even possible), and I don't think a single air/air will be able to handle the task.

[Kohburn]

just bandsaw one end tank off and TIG weld it back on


thats how i turned one of these into this

[Shaun41178(2)]

The turbocoupe a/a intercooler you have is way too small for the 400 ponies you are making. I wouldn't try to use that. It will really restrict flow in the middle to higher boost settings, and thus create way more heat then it can pull out.

I realy think you want to stick to a/w if you can. You already have the parts yes? Stick with that, and find a way to either reroute the plumbing, or modify the intercooler how you need. Or find one online, or have someoen custom make you one to fit how you like. YOu can run ice water through those really bringing temps down, plus water transfers heat much faster then air obviously since the molecules are closer togethor.

Any pics of the proposed setup with the a/w?

[TurboGT]

I got mine off a Typhoon and there have been tons of people that have cut off the inlet and welded on a different setup for more flow.

[p8ntman442]

Build a completly custom hand made a/w unit and model it in femlab. That way you can check out the performance using FEA and develope a really kick ass setup. Your just making a heat exchanger, so the only possible part that could pose a problem would be the fins on the air passage.


Did you say turbo coupe..... I think you deserve a kick in the nuts.

[bryson]

Haha yeah, I did. Sorry it was late, I was studying for my 8am final and just never went to sleep. I was taking a break and found my old picture


--I thought it was crazy cool looking, that's really the only reason I wanted to do it :la: Anyway, I'm gonna stick with the water/air unit, but I haven't decided if I want to try and make new endtanks or sell mine and buy one of the cheaper ebay units.