Technical Fitting a bigger intercooler

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Technical Fitting a bigger intercooler

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Has anyone tried fitting a bigger intercooler at the original place ?

JTD115
 

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No guys, it's not.
It runs just fine. I've tested the hose with foam, it's ok.

Going to bypass intercooler this weekend, cause i'm fighting with whooosh sound.

And btw was interested in fitting a bigger one cooler if that's what is causing the whoooosh :)
 

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If you can hear a whooshing sound your probabely loosing boost. Use a spray bottle with a 50/50 mix of washing up liquid and warm water. Spray it all over the intercooler, any escaping air(boost) will cause bubbles to form. This also works on the ducting and joints, give them all a good soaking and look for any bubbles forming.
 
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pros
lots of colder air

cons
big ICs inherently create lag

solutions
hybrid or bigger turbo.
alternatively designed IC.

basically if you can match or better your IC Volume over a larger surface area then you're much better off!

for instance if your current IC is 10"x6"x2" if you can figure out a way of getting a 20"x12"x1" in there the volume will remain the same BUT it will be more effective due to the halved thickness. where as before the 2nd inch was down stream of the first inch it would not have the same temperature air flowing over it, it would be warmer due to the heat picked up from the first inch, if that makes any sense. also if you have a greater number of thinner galleries in your core then you increase the effective surface area.

look into maybe getting a secondary washer bottle plumbed in and rig up a water spray system. ideas for this could be a load of spray bottle nozzles in a manifold of some description fed by a headlight washer motor for the increased pressure required for using the spray bottle nozzles. i could give you ideas all day long but i dont know really what your after!
 
That's mine in shadys pic higher up, to be fair even at 26psi on the original intercooler I only had +30c +40c above ambient on a hard run. With that toyosport eBay cooler on there I only see +10-+15c above ambient max @26 psi .
I would say lag increased on std turbo a tiny bit.
Unless your boosting higher and suffering with high boost temp(50c+) it's probably not worth it.
Also bear in mind cooler intake takes longer to warm up engine, I'm half way to work before gauge hits midway in winter.
An alloy intercooler in the original position but thicker would have been easier with regards to extra pipe work needed for fmic, but would need to be custom made. A fmic and all pipe work and clamps etc should be approx £150.
And more expensive coolers may be better, but some cheap ones can flows o.k too.
 
Whats the rad on the left corner, if its not a intercooler what is it and is it not on the wrong side if it is a standard intercooler.

Nice set up though. What power you running with that and you got a Jtd or multijet?
 
Jtd 150 16v, yes it's std oil cooler.
Forgot to mention you'll struggle to get fmic in place without a few mods to grills bumper etc.
That's flowing enough for 95.5mg/i fuel with afr 16.5:1 @ 1750mbar around 4000revs and only 12*c above ambient. Hopefully around 440nm@2750 and 410nm@4000
Hybrid turbo and fully decated help no doubt.
No r/r print out so please don't ask, these figures are from the figures in map as requested(already minus internal friction loss from its own map, requested nm is closer to 490nm)
 
if it helps ive dug back and ill try to get all related pics up in here.
here is available frontal area in cowel
s1030384.jpg
s1030385.jpg
s1030386.jpg
old vs new
fmic instal3 001.jpg
cut crash bar and bolted through from above
fmic instal2 004.jpg
rough idea fom above where its siting
fmic instal2 005.jpg
tried to keep bends fairly tight, youl see why in a bit
fmic instal3 010.jpg
hopefully other models have less other stuff in the way and a better route is available
fmic instal4 012.jpg
required drastic surgery to cram in
fmic instal4 013.jpg
fmic instal4 003.jpg
you can see black cut lines marked in central grill
fmic instal2 007.jpg
you can see no route with original grill openings
fmic instal2 011.jpg
fmic instal3 007.jpg
large amount taken out of side grill opening
fmic instal2 013.jpg
thinner new grills
fmic instal2 016.jpg
painted black at finish due to being a bit blingy through the grills
a slightly shorter fmic would have helped a lot with grill and bumper mods im guessing, but this one is maximising the available airflow.
ive seen a few massive intercoolers on some cars that 1/3 of the frontal area is covered by crash bars etc just seems a waste to me.
if id have known how hard to cram it in i would have got the intercooler outlets cut and rewelded at an angle would have helped a bit.
 
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Hats of to you, that is one really tidy install.

So what power output are you getting with that bigger inter-cooler and any other engine mods, Guess you have a trick turbo??
 
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