Warter - Air intercooler

[ColtArt]

Stage 1 - select new intercooler complete
PWR air Water 200HP easy upgrade to 270 HP kit

Stage 2 - design new pipe system, find parts for said system
complete (interestingly a mandrel bent pipe system to copy the ralliart ones, mandrell bent. a measly $150 from my local Xhaust shop $250 in stainless. verdict, incompatable with my new system! (DOH)

Stage 3 - make it fit
this weekend i will be fitting the water radiator and pump to my car with the objective of finishing hte system by next weekend if not this weekend.

Total cost so far for all pipes and intercooler, $1275. petrol wasted trying to find a 2 inch turbo pipe :mad: $700000000 finally ended up using old hoses from a MR2 intercooler from the wifes car spares bin.

Next week : Stage 4 - on road testing! :eek:

[we1hu1]

U did an intercooler relocation? :eek: Share the pictures with us!!:D

[ColtArt]

here is hte bits
i finally figured it all out.

http://img295.imageshack.us/my.php?image=uploadgg8.jpg

the radiator and fan for the water will be going on hte passanger side of hte car infront of hte radiator. this is a large part of the work as i have to secure it without puting any holes into hte car that could cause rust

super heavy insulated (to keep engen heat out) water hoses will then be linked to the water pump (black thing). the water pump will then push hte cold water into the top of the intercooler barrel which will be mounted verticly with the top going into the in tack and the bottom reciving the turbo heat. the heated water will leave the barrel via the bottom of the core and go into a filter/ filling point before returning to the front of the car where it will be cooled off.


the air will leave hte turbo, go into the new mandrel bent 90 degree pipe and go stright up into the intercooler which will use a flexable (for movement) rubber hose to put hte air into the intake plenum.

the airflow path of this setup more then halfves that of hte original and has a lot less bends. i am hopeing to see more real boost (AWI's like this lose only .7-1 psi vs 2-5 psi of a normal setup) enter the engine and at a lower RPM

[Steve-B]

Please keep this thread up to date, so we can all learn from what you have done, some more pics of location and explanations of what you are doing and done in detail would be much appreciated.

[27AME]

Can I just ask why you didn't go for a larger Air - to - Air? I have spoken to PWR and it's entirely possible.

[ColtArt]

Stage is still at making the thing fit in a professional matter.

i am probibly going to have to take hte front bar off (as you would with other intercooler installs) so i have been putting it off till this long weekend. oce i am that far i will take more photos

Reasons for water insted of air to air are not because air to air is not possible, far from it, it is actuallay easyer then this install as it does not require water or eletrical componants.

reason 1. off the line heat soak of air to air coolers is terrible esp with small engines like ours that depend upon the turbo. water to air will significantly improve off hte line response in this regard alone.

reason 2. more boost for less. a standard intercooler will lose 2-7 PSI between the turbo and your engine depending on size, hoses etc. this is due to all the pipes, bends and the restrictin on the intercooler it self. basicly your pushing air through a lot of hose its going to lsoe pressure.

the water jobbie will go from the turbo, up into the intercooler and stright into the engine. this will mean a total of 2 bends insted of the 5 that currently exist and hoses 1/2 then length.

but these gains have two compramises.

i have to deal with water / electronics. having done a lot of kits and mods on other cars i am confident of the level of skill i have to do this.

the other compramise is that i will have a water radiator infront of my other radiator which wont look too cool compared to a normal intercooler :confused:

[Steve-B]

Hey Coltart,
I have been looking at the image you posted of the pwr kit, can i ask some stupid questions. I guess that the cooled water goes through and round the chrome pwr after being cooled in the mini radiator you have and then back into the system. So the "cooling part" is when the compressed air after the intercooler goes through the pipe with pwr on it before the intake ?
if someone has a link or image of how the kit works it would be much appreciated, as i agree with coltart, the heat soak of sitting, waiting for the launch the air wont be as cool as if you were in motion.
Cheers
Steve

[ColtArt]

http://autospeed.drive.com.au/cms/A_2922/article.html

http://honda-tech.com/zerothread?id=1690070

theres plent of info and installs if you google them. ive seen them mainly in drag cars and small turbo installs like ours

[Steve-B]

any news on how it is going, pics of where you are locating stuff ?

[Steve-B]

still no news....man you had all easter long weekend !!!...lol