Technical Fitting a bigger intercooler
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Technical Fitting a bigger intercooler
I'm not sure thats possible, there just not enough room in the original place.
Maybe fatter one will fit.
All the Stilo's I've seen with upgraded intercooling look like this.
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Rather than increasing the size of the intercooler why not increase its efficiency by adding an Intercooler Water Spray System?
http://www.airpowersystems.com/wrx/my01/water_spray/water_spray.htm
CO2 Intercooler Systems are supposed to be even better ...
Some are made to look like NO2/CO2 purge.
http://www.airpowersystems.com/wrx/my01/water_spray/water_spray.htm
CO2 Intercooler Systems are supposed to be even better ...
Some are made to look like NO2/CO2 purge.
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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
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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@Shadeyman - that's exactly what i did, no bubbles.
Here's what it sounds like - http://www30.zippyshare.com/v/98476724/file.html
from 3rd to 5th second.
Most heard during acceleration between 2200rpm and 3000rpm. Sounds exactly like a blow off valve.
Here's what it sounds like - http://www30.zippyshare.com/v/98476724/file.html
from 3rd to 5th second.
Most heard during acceleration between 2200rpm and 3000rpm. Sounds exactly like a blow off valve.
doesn't fitting bigger intercoolers create more lag?
would it not be better to find a more efficient I/C i.e. a better constructed core?
would it not be better to find a more efficient I/C i.e. a better constructed core?
Is this right? I thought It'd be quicker because the air would be cooler and more dense?
I'm looking at a getting a big FMIC, just investigating the pro's and con's at the moment
Owen.
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!
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.
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.
Here's a comparison fmic to smic I think everything else was same.
http://www.alfaowner.com/Forum/atta...-fmic-for-147-1-9-jtd-8v-fes-smic-vs-fmic.xls
Boost doesn't go as high with fmic as I think extra volume and bends reduced the boost creep I was suffering with tuning box.
http://www.alfaowner.com/Forum/atta...-fmic-for-147-1-9-jtd-8v-fes-smic-vs-fmic.xls
Boost doesn't go as high with fmic as I think extra volume and bends reduced the boost creep I was suffering with tuning box.
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?
Nice set up though. What power you running with that and you got a Jtd or multijet?
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oil cooler
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)
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
old vs new
cut crash bar and bolted through from above
rough idea fom above where its siting
tried to keep bends fairly tight, youl see why in a bit
hopefully other models have less other stuff in the way and a better route is available
required drastic surgery to cram in
you can see black cut lines marked in central grill
you can see no route with original grill openings
large amount taken out of side grill opening
thinner new grills
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.
here is available frontal area in cowel
old vs new
cut crash bar and bolted through from above
rough idea fom above where its siting
tried to keep bends fairly tight, youl see why in a bit
hopefully other models have less other stuff in the way and a better route is available
required drastic surgery to cram in
you can see black cut lines marked in central grill
you can see no route with original grill openings
large amount taken out of side grill opening
thinner new grills
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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