Intercooler Temps - Before/After Comparison

[Noz]

Thought I'd post some information regarding the drop, and reduction in temperature across my intercooler and also ask about the output temps of my turbo.

 

Crusing at 80. 20° drop: 40° from the turbo, 20° out the cooler.

 

Crusing at 60. 10° drop: 32° from the turbo, 22° out the cooler.

 

Crusing at 50. 9° drop: 26° from the turbo, 18° out the cooler.

 

On full boost at 4.5k Im pushing 53° out the turbo, and 19° out the cooler. Obviously this is at speed.

 

Full boost at 5k Im pushing 55° out the turbo, and 21° out the cooler.

 

 

I'm really impressed how equal the temp's are even with flow dramatically changing at decent rpm ranges.

 

If I hold on full boost for long enough I'm sure I'll hit above 60° coming from the turbo. Be good to see how much a co2 kit could drop temp's even more and compare the results on a dyno.

 

Does anyone else moniter stuff like this or have similar values?

Edited April 24, 2013 by Noz (see edit history)

[Shane]

I bought a couple of these to do exactly this, but have such a long list of things I need to do now after 12 months of crap weather its well down in terms of priorities.

http://www.ebay.co.uk/itm/DIGITAL-FRIDGE-FREEZER-PROBE-THERMOMETER-TEMPERATURE-GAUGE-METER-MONITOR-DISPLAY-/321090293725?pt=UK_BOI_Electrical_Test_Measurement_Equipment_ET&hash=item4ac2790fdd

[Noz]

Look's like a much cheaper way of doing it than me. My dual intake sensor gauge cost £55 quid. But it does resolve the concern of locating it.

 

It would be interesting to see what differences a variation on intercoolers would make.

 

Apart from flow testing them, I must say everyones comments regarding cheap eBay intercooler setups is nonsense, as the temps are constantly reduced.

 

For anyone else wanting to go NA-t or small single, I'd highly recommend not wasting money on a 600quid intercooler. My whole setup cost £150 and these temp's are constantly low.

[David P]

What pressure drop does that cooling cause?

 

I haven't monitored the before and after temps with my charge-cooler, there aren't enough gauges, but turning it on drops the charge pressure from 12.5psi to 11.5psi.

Edited April 24, 2013 by David P (see edit history)

[Noz]

No idea, I would need a boost gauge before and after. The drop in pressure should be a benefit I would of thought, more volume with less pressure would inturn create less compression in the stroke of the engine, having a cooler combustion process surely?

 

I read somewhere a lower pressure and temp in the chamber will keep the temps down (think it was when research meth injection)

[David P]

Blank the I.C. off and give it one blip, you'll soon see.

 

Or it could be tinkered out with Charlies law.

[Noz]

I'd want to compare both while running mate. I will have a look online see if I can find a dual boost gauge. That would be the nuts. I currently don't even have one. Removed it as it went faulty and was contemplating getting an AEM boost controller, gauge included,

[Shane]

Look's like a much cheaper way of doing it than me. My dual intake sensor gauge cost £55 quid. But it does resolve the concern of locating it.

 

It would be interesting to see what differences a variation on intercoolers would make.

 

Apart from flow testing them, I must say everyones comments regarding cheap eBay intercooler setups is nonsense, as the temps are constantly reduced.

 

For anyone else wanting to go NA-t or small single, I'd highly recommend not wasting money on a 600quid intercooler. My whole setup cost £150 and these temp's are constantly low.

 

I think with a little bit of tweaking they will sit in the slots next to the slip control switch, they are a few mm bigger than the opening.

 

Yours does look efficient that's for sure. Sadly, a lot of people believe if it came from ebay and not a trader then its rubbish. I am sure that is the case with some kit, but not everything and in the case of the intercooler I guess its a case of diminishing returns. You may get a slightly better efficiency but that increase is going to cost a whole lot more.

[imi]

Apart from flow testing them, I must say everyones comments regarding cheap eBay intercooler setups is nonsense, as the temps are constantly reduced.

 

For anyone else wanting to go NA-t or small single, I'd highly recommend not wasting money on a 600quid intercooler. My whole setup cost £150 and these temp's are constantly low.

 

What IC did you go for?

[Tricky-Ricky]

The increased air density should more than make up for the small pressure drop, and then you can just turn the boost up a bit;)

[Noz]

What IC did you go for?

 

http://www.ebay.co.uk/itm/3-UNIVERSAL-INTERCOOLER-KIT-TYPE-VB-600x300x76MM-U-BENT-PIPING-KIT-BLACK-/140622348926?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item20bdbec27e

 

 

The increased air density should more than make up for the small pressure drop, and then you can just turn the boost up a bit;)

 

Well I hit 1.2bar and Austec said I didn't have any knock whatsoever. I'm hoping EGT will be reasonable as well, though I need to know what they are for sure.

[Pulley]

That's good cooling figures mate

A pretty efficient turbo setup, sounds like you've got a well matched ic for your turbo/boost levels

 

Only real difference in SOME cheaper intercoolers is the vein design , two intercoolers with identical outer dimensions/ volume and resistance to flow can give quite a different level of cooling

 

Most of the coolers I've seen on eBay have been pretty good and equal in efficientcy to all apart from some of the very high end custom design coolers

[Noz]

Cheers mate. Be good to flow test a couple to compare results? Wonder if anyone has a top-spec cooler they wish to let me borrow? I'd be up for some decent comparisons

[Pulley]

Cheers mate. Be good to flow test a couple to compare results? Wonder if anyone has a top-spec cooler they wish to let me borrow? I'd be up for some decent comparisons

 

I have some custom core's I haven't finished yet, mine is a 4" wide "dimpled" vein and staggered wave infills between,

Same design I use on customers ultima's ect

Just more expensive to manufacture, and unless your pushing 600+ Bhp the benifits over slab style veins isn't really worth the extra expense lol

 

I'd say the figures your achieving are very good mate

[Noz]

Thanks dude. Be good to compare against your custom coolers though?

 

I would assume the only benefit with higher flowing coolers would be grasped with a serious amount of flow, as the cooling effect would need to be as fast as possible if the time the air stays in the cooler is reduced due to higher air speeds or lower surface area covered with higher pressures.

 

Keep me posted when you finish I'd love to compare (and maybe even buy one results depending).

 

Really am surprised no one actually looks into their air temperatures. Do most people just slap one on assuming it works?

[mellonman]

what else can you do about it , even if you got high figures back lol , alot of cars run without intercoolers at all so having one fitted is better then none at all

[Pulley]

Only real difference in like for like sized coolers is that often a more simply designed cooler will restrict the airflow more exponentially as flow rate increases , and often the vein design may not allow the cooling air to flow thru it as cleanly (again restriction increases exponentially as airspeed increases)

 

Producing a cooler that allows charge flow to pass freely thru it well is easy, designing one to allow free flow AND give good heat transfer with cooling air able to take the heat away is harder

Curved coolers ae better and increase surface area as well as helping to channel the cooling airflow thru its fins better (likes one bike radiators)

 

Give me your mounting dimensions mate and ill finish the ends on one of my cores I have and do a comparison on your setup

[Noz]

what else can you do about it , even if you got high figures back lol , alot of cars run without intercoolers at all so having one fitted is better then none at all

 

You can't do anything about it if you don't know it's a concern, and you don't know it's a concern if you don't consider it's effects. I'm looking at the flow and performance of this modification to ensure it's working.

 

If you fit an intercooler that's not working correctly, how would you know? The result is less power, which you wouldn't want, but would never consider? A lot of changes and upgrades don't always perform as well as they should, that's something really important.

 

I'm not saying you could make a difference, nor would it be a serious problem. But if you can push higher power figures just by component selection from technical data isn't that a factor worth considering

 

Only real difference in like for like sized coolers is that often a more simply designed cooler will restrict the airflow more exponentially as flow rate increases , and often the vein design may not allow the cooling air to flow thru it as cleanly (again restriction increases exponentially as airspeed increases)

 

Producing a cooler that allows charge flow to pass freely thru it well is easy, designing one to allow free flow AND give good heat transfer with cooling air able to take the heat away is harder

Curved coolers ae better and increase surface area as well as helping to channel the cooling airflow thru its fins better (likes one bike radiators)

 

Give me your mounting dimensions mate and ill finish the ends on one of my cores I have and do a comparison on your setup

 

Will do mate. I shall copy you in later tonight on facepad.