Intercooler Options

[Coops]

I'm still having cooling issues with this huge cosworth intercooler in front of my rad.
1: What is the smallest intercooler I can safely go to?
2: Or is there other options I can look at?
3: Or do I need an intercooler at all?

As always you guys are the best to ask

[JP.]

blablabla
3: Or do I need an intercooler at all?

That should be the first question before you did all the plumbing but...

What I did with my V6 turbo project before I started intercooling plumbing..
I bought this http://www.ebay.co.uk/itm/Digital-Therm ... 3386d05cc5

And this http://www.ebay.com/itm/-/130728053100? ... OU:NL:3160

I just did stick the sender in one of the intake charge pipes close to the intake manifold where there was a hose connection.

You need the step down regulator as these simple gauges are 5V only (PC gauge ).

So get that big intercooler out, make a temporary re-plumb so you can run it without the intercooler. Fit this cheap intake charge temp gauge and then you have the answer if you need an intercooler at all.

Btw I just fabbed a simple bracket that holds the gauge. Its still in situ and shows me data when I want it. It showed me I didn't need an intercooler in my situation at all.

Hope you can do something with this info and cheap trick.

[stevieturbo]

I cannot believe the intercooler is the problem.

I can believe the water rad may be the problem, or some other issue.

Ive a 4.5" thick intercooler covering almost the entire frontal of my water rad, and have no issues at all with cooling. My water rad sits about 2" directly behind it, although does extend maybe 1.5" lower than the intercooler.




However....as a relatively cheap test. You could buy a cheap 4x4 Cossie intercooler which is only 5-6" tall and fit it in place of the larger unit. Think they go for £50 or so on egay and should almost be a straight swap for you.

Some pictures of the two here. Although I did think the 2wd and 4wd were the same width.

http://passionford.com/forum/ford-rs-co ... -bits.html






When exactly does the overheating occur ?

[Coops]

mainly in traffic mate,
I have the cosworth fans on the rad and two 9" helper fans blowing through the intercooler,
it has helped but takes ages for the temp to come down and turn fans off,
and its still pretty cool outside, I know whats going to happen in the summer its just going to cook

[stevieturbo]

Have you made sure no hot air can recirculate and get blown back through the core ?

Cossie rad is quite short, do you have room for a taller one ?

With 4 fans, airflow itself shouldnt be an issue..

Does it overheat sitting still, but with bonnet open ? ie less chance of recirculating hot air through the core ?

[r2d2hp]

Here is a log I took last year with no intercooler fitted. Not running anywhere near your boost and I think my tems are already too high. Maybe Stevie could advise


AirTemp Rev EGT PSI
68 4848 649 5.80
68 4855 649 5.80
68 4863 649 5.80
68 4865 649 5.80
68 4904 649 5.95
68 4911 649 5.95
68 4904 649 5.95
68 4909 649 5.95
68 4928 649 5.95
68 4946 656 5.95
68 4943 656 5.95
68 4951 656 5.95
68 4951 656 5.95
68 4956 656 5.95
68 4958 656 5.95
69 4978 656 6.09
69 4983 656 6.09
69 4988 656 6.09
69 4996 656 6.09
69 5009 656 6.09
69 5019 656 6.09
69 5027 656 6.24
69 5042 656 6.24
69 5045 656 6.24
69 5053 656 6.24
69 5073 663 6.24
69 5073 663 6.24
69 5081 663 6.24
69 5105 663 6.24
69 5102 663 6.24
69 5100 663 6.24
70 5118 663 6.24
70 5126 663 6.24
70 5132 663 6.09
70 5129 663 6.09
70 5134 663 6.09

[stevieturbo]

There will always be variables

Would need to see a more complete log really. EGT's look low though

Air temp, 70degC is very possible with no intercooler, although that would probably be as high as I'd ever want to see charge temps.

That said, if you arent running close to detonation, CR is sensible and timing isnt overly retarded, then it should still be a reliable setup despite the higher charge temps.

I'd always try to run an intercooler though

[r2d2hp]

Tony asked point 3 asked do I need an inter-cooler.

I think the answer is yes based on my experience and I am taking cold air from outside the engine bay. Would assume with 14psi boost an no inter-cooler things would become unstable

Stevie - in your opinion what would be the max intake temp you would want to see before becoming concerned?

[Eliot]

I wouldn't want my temps much above 60'c on a regular basis - could live with the occasional spike as a result of a hot day and a lead foot though.

My view is that you should always fit an intercooler.

[SuperV8]

How close are the radiator and the intercooler?
They should be as close as possible without touching, if there is a large gap between them air with stagnate and you'll get poor air flow through the rad behind. Read that in one of my tuning books!

The higher the boost the more important/worthwhile an intercooler. At 14psi I would say you defiantly should be using an intercooler.

Tom.

[stevieturbo]

Tony asked point 3 asked do I need an inter-cooler.

I think the answer is yes based on my experience and I am taking cold air from outside the engine bay. Would assume with 14psi boost an no inter-cooler things would become unstable

Stevie - in your opinion what would be the max intake temp you would want to see before becoming concerned?

To a degree it is an open ended question.

If you build the engine knowing air temps will be hot, and monitor EGT's etc, then even 60deg, 70degC wouldnt really be a problem

Even 100degC could be fine.

It isnt ideal, it isnt best for performance or anything really, but that doesnt mean a combination cant be built to live with it.

It would of course require much lower CR compared to a build with lower charge temps though.

But as long as the engine is detonation free, EGT's are within safe limits then actual charge temps dont matter that much.
Of course performance will suffer, but it doesnt mean the engine cant be run like that.

But I personally dont like seeing charge temps much over 40degC, although again that will vary on ambient conditions. Here I rarely see over 20degC ambient, only on rare days in summer. You guys seem to get warmer weather in England during the summer.
So if Ambient was 40degC, it would be expected for charge temps to be higher.
But then I also use water/meth to ensure they always stay as cool as possible, plus the water/meth offers huge detonation resistance.
For normal road use etc, I dont use water/meth though. Just isnt needed in general

[r2d2hp]

Thanks Elliot and Stevie. Issue I has is there is no room on MK1 capri for a reasonable size intercooler. I tried a small one and had same issue as Tony hence I had to remove it. It was also a boost limiter.

I am moving to water meth injection to reduce my intake temps so will aim to reduce to 40 degreess - thnaks

[stevieturbo]

Capri has a very long nose....with some thought, angle grinder etc...there is always room.

[Coops]

Reg wait to see if the mods Serck are going to do on my rad work.
If so maybe an option for you to then mate.

[JP.]

Tony did you ever measured intake temps ???
Or are you just ignoring it.

Measuring is knowing.

Btw. 10 degree drop in intake temperature equals 1 bhp. (its in most books)
To high an intake charge temp will harm that's where the intercooler comes in.
But basically if you don't know what the readouts are with and without an intercooler in your particular situation where are we talking about.

Tony, I am not making a fight, will bring you waffles this year..... but trying to wake you up.
Like R2D2HP, measure temps and work from there.

Reading this post is like, he.. I have a rattling noise coming from the engine... answer whats the oil pressure...answer back.. I don't know, aint have a pressure gauge...