How to build an intercooler

[Ondonti]

When you run a "more tubes, less length" intercooler and rely on air slowing down as it goes through the greater number of tubes, it works great at a lower HP number. At a high HP number you don't have a restriction but now the air is moving quite fast and while its making more power then a long intercooler with half the flowpath, its not going to cool well. It works well as long as you are nowhere near the limit of the flowpath. I guess you need both the flowpath AND the cooling capacity required for your turbo outlet temps. If you run that super huge intercooler at half capacity, then you will not be as happy as the version with less cooling capacity or just an overall smaller intercooler. Low boost setups don't put as much heat into the charge so they can get away with a different intercooler style too. Then I have heard E85 guys sometimes ditching their cooler.

[8valves]

I have only backpurged on aluminum in rare cases on old used parts to try to help. Other than that with aluminum it shouldn't be necessary. Also on my intercoolers i weld the inside ofnthe seams and the outisde, where possible. You could also call it GTAW welding. But TIG is easier.

Cordes, simply for packaging and appeaeance. I like the added symmetry with the mirrored tanks. And no, ive never done routing baffles inside a core.

Its tough to describe about the idea behind the core. I tjink Ondonti is getting what im trying to say. You need to find a compromise between flow and restriction. I like to use Garrett cores because i have had great luck with them doing the hard work of the design process on the core, then i just have to make a nice directional end tank.

---------- Post added at 07:06 AM ---------- Previous post was at 06:59 AM ----------

As promised IC is mounted and charge and intake plumbing tacked up. Should be finish welded and up and running later tonight if things go well.

[iTurbo]

Wow, very nice!

[Force Fed Mopar]

So essentially choosing a cooler is simply finding the right compromise between flow and cooling, correct? I think that is easy enough for us all to grasp. What isn't easy for most, is how do you tell how much compromise there is? Tube size, tube spacing, length, etc, we know they are factors, but how do you tell how much of a factor each one is?

Maybe we need a new thread to discuss Started one here:

http://www.turbo-mopar.com/forums/sh...747#post869747

[Vigo]

So between your header and this intercooler im figuring the guy is going for a larger than stock turbo as well. What turbo is on this van? I assume it's something relatively mild since it still has a 1pc on it.

[8valves]

So between your header and this intercooler im figuring the guy is going for a larger than stock turbo as well. What turbo is on this van? I assume it's something relatively mild since it still has a 1pc on it.

Yup, pretty mild combo to just be fun and useable. It has the header and turbo (Mopar + unit) from the Daytona.

It was on a Mitsu and +40's with a RRR and AFPR, and a G valve boost control, and a cut out raiser bleeder. I got rid of all that and did a 3bar calibration and boost control, the header/turbo, the IC, and a downpipe without a section of 2 1/4" in it like the old one had. And a fuel pump/filter, etc.

It made 176whp/261 WTQ at 18 psi when it came in. Dyno to follow on how the changes helped out. I'm hoping for 260WHP/330 TQ. It's a factory 5 speed van too, and minty clean.

I think the next round of mods will be a modified intake manifold and a 3" swingvalve. And a clutch, lol. After that maybe spray it and outrun Simon's mega-fancy race van, haha!

[turbovanman²]

Yup, pretty mild combo to just be fun and useable. It has the header and turbo (Mopar + unit) from the Daytona.

It was on a Mitsu and +40's with a RRR and AFPR, and a G valve boost control, and a cut out raiser bleeder. I got rid of all that and did a 3bar calibration and boost control, the header/turbo, the IC, and a downpipe without a section of 2 1/4" in it like the old one had. And a fuel pump/filter, etc.

It made 176whp/261 WTQ at 18 psi when it came in. Dyno to follow on how the changes helped out. I'm hoping for 260WHP/330 TQ. It's a factory 5 speed van too, and minty clean.

I think the next round of mods will be a modified intake manifold and a 3" swingvalve. And a clutch, lol. After that maybe spray it and outrun Simon's mega-fancy race van, haha!

Very cool, does the A/C work? I liked where you put the IC, barring of course the A/C is still functional,

Why does everyone pick on my van,

I wouldn't call it a mega-fancy race van but a mega-heavy daily driver, kid/dog/wife/crap hauler and sometimes race van,

[8valves]

Compared to this thing your cammed, GT35R, built auto, built motor, custom intake, Lotus headed van is indeed mega fancy compared to this thing, haha!

And yes, the AC is fully functional, hence the purpose of this particular IC setup.

[turbovanman²]

Compared to this thing your cammed, GT35R, built auto, built motor, custom intake, Lotus headed van is indeed mega fancy compared to this thing, haha!

And yes, the AC is fully functional, hence the purpose of this particular IC setup.

Not cammed anymore,

Cool, literally. Wasn't sure it was still functional, everyone removes it. Got a pic of the A/C side?

[fishcleaner]

Great post, how long have you been welding? the welds look amazing.

[mcsvt]

Looks great Aaron, that would be really nice to have in my van. Maybe when I get the motor refreshed after winter I can figure out a similar setup.

[8valves]

Thanks, about 4 years or so daily, with a year of learning/basics prior to that.

Van is done and ready to dyno, but the tuned ECU has a bad internal voltage regulator so it will have to wait a bit. I will put up the finished pictures after i shower and theyve uploaded.

I think it turned out very nicely. It appears small through the grill, but should support more power than it will ever need to.

[cordes]

Thanks for the update Aaron. I appreciate your responses on here. It's a real learning experience.

[8valves]

And here are some other SS welding pieces ive fabbed and done recently that tend to be a little more complex.

[Force Fed Mopar]

I would so paint that intercooler black

[Vigo]

It was on a Mitsu and +40's with a RRR and AFPR, and a G valve boost control, and a cut out raiser bleeder.

It made 176whp/261 WTQ at 18 psi when it came in

Wow. Having you lend some guidance and mechanical skill to that van build is probably the best thing that could have happened!

Im interested to see what it does on the dyno. I think you'll be pretty close considering this is overall a better setup (sounds like) than the daytona and that thing was pretty much there, aside from the 2.2/2.5 torque difference. Although, did your daytona have a stock 1pc? If not i could see that having some effect.

I would so paint that intercooler black

I agree.

[turbovanman²]

Mad skillz Aaron, wish I could weld like that.

Looks really good, Pretty funny, mine looks the same thru the grill but mines on the other side,

I would so paint that intercooler black

I would so not, lol.

[Ondonti]

F you on that twins setup Aaron, that just looks like too much fun. Is it running yet?

[8valves]

I would so paint that intercooler black

The customer requested that it stay visible.

Wow. Having you lend some guidance and mechanical skill to that van build is probably the best thing that could have happened!

Im interested to see what it does on the dyno. I think you'll be pretty close considering this is overall a better setup (sounds like) than the daytona and that thing was pretty much there, aside from the 2.2/2.5 torque difference. Although, did your daytona have a stock 1pc? If not i could see that having some effect.


I agree.

That's actually the intake off of the daytona, and yes it is stock. I couldn't do all of this work and put the nasty dirty silver one piece back on.

F you on that twins setup Aaron, that just looks like too much fun. Is it running yet?

Sure is. Wait, the van or that system i put a pic of up? Either way yes, they both are running, haha. That system was a bit stressful actually. Got a little over zealous with the visual idea that ended up being very difficult to execute, but in the end it was a challenging experience... Which i guess ultimately makes it fun AFTER it's done.

[Mopar318]

What are those mini cylinders after the turbine outlet?