Water to Air Intercooler setup

[dilmah]

Toko it for a good run on Roe and Tonkin Highway today, sat on 105km/hr at 2500rpm.
Was getting pretty constant temps. Turbo side was 120 - 125, inlet side was 90 - 85. average drop of around 30 degrees. Ambient temp was 25 degrees.

 

[baitfish]

Ordered the new w2a cooler mate?

 

[dilmah]

Yeah its here, came on the Sunday before Christmas. Just waiting to get a few days off work to install it. I bought some hose clamps today and put the waterline fittings on the new cooler. I will most likely do it on the 4th - 5th as I have a few days off work. Stay tuned, the end is in sight

 

[baitfish]

sounds good man.

 

[dilmah]

So its finally finished! Took about 4 hours to fit the cooler and the rest of the piping and to fill the unit with water. Firtst few runs I noticed the nav pulled a lot harder from 1600 - 300rpm. Intake temps rarely get over 50 when cruising at 100km/hr wheres before they would be up around 70 - 80. Will be interesting to see if I get better fuel economy.

 

[4BYFOR]

Nice work mate

 

[dilmah]

After a few more days of driving I have found the system to be very efficient, I'm getting intake temps 10 degrees above ambient as an absolute max. Even on a 40 degree day the highest intake temp I got was 52. I still havnt tested the it on the highway yet, will try and take it for a run in the next few days and see how she goes sitting at 110 - 120.

 

[ben85]

sounds good dilmah.

what are the details of the parts u used to put the system togeather?

 

[happy john]

That's a good result after your hard work looks good too well done mate you should get better economy if it's burning more efficiently and you don't have to give it as much to get it going.

 

[baitfish]

that's decent results dilmah, good to see that your set up can handle the high temp days. Will be interesting to see if it can handle the heat soak on the long runs.

 

[dilmah]

Parts List - all frozen boost unless specified

Heat exchange - Type 100 24" x 12" x 1" (Just fits between bullbar mounts), will have to move some minor grill brackets and horn
Intercooler - 12.25" x 12.25" x 4.5" Typre 14
Water pump - Bosch unit and wiring harness
Cooling fan - 12" x 2

Turbo piping
2" - 3" reducer
2" - 3" 90 degree elbow
3" elbow
3" Aluminium joiner

All water piping, hose clamps and brass fittings bough at my local fittings shop
All wiring, crimps and switches were bough from my local auto shop

Total cost minus the guages would be around the $800 mark. I did get alot of the kit second hand and the wiring was already done from my previous thermo fan.

Id allow $1000 for anyone else attempting this mod as costs can quickly blow out if you dont get the right parts from American where components are dirt cheap. e.g. a 3" 90 degree elbow is $20 in the states yet $70 here. I had to buy a second intercooler as it was too hard to do the piping with the one I got second hand. This added another $250 to the price when you add in exchange rate and shipping.

 

[ben85]

well at least it seems to work well, ill await ur further results for confirmation

 

[dilmah]

Yeah ill take it for a long highway run tomoz. The daytime temp will be in the low 30's and I will take her for a 30 - 40km run down one of my local highways where I can get to 110km/h. This will be the true test for heatsoak and the radiator's ability to dissapate the heat

 

[dilmah]

Alrighty - Highway run DONE! sitting at 2500rpm and about 107km/h the outside air temp was 28 degrees at 10pm at night comming off my scanguage. Pre intercooler - 120 degrees, Post intercooler 50 degrees and water temp was 46 degrees. A massive 70 degree drop over the intercooler.

Be mindful that im running 16 - 18psi of boost, a Mk1 chipit on setting 5, a 3" exhaust, EGR blocked and im not sure on the air filter.

The only problem I have atm is I keep blowing the intercooler piping off just past the turbo. I need to get smaller hose clamps as the ones I have are already at their tightest adjustment.

Future mods may include a Mk3.1 dual map chip from Chip it and 20 - 22psi of boost. Dont want to kill the motor though so I may leave the boost where it is.

 

[Navmania]

That's a great result mate. Bet your happy with that. They can take a fair bit of boost so crank it up a bit and see what it does. I have heard of them being boosted to 22-25 psi with no problems.

Cheers.

 

[baitfish]

Dilmah,

that's great results man, will be looking into upgrading the radiator for my set up in the near future!

cheers

 

[dilmah]

A general rule of thumb I have found is that when travelling under 80km/h the post intercooler temp is less than 10 degrees above ambient, this rises to about 20 - 25degrees when travelling at highway speed.

 

[dilmah]

Bit of an update on this build, I decided to permanently mount the gauges in the din below my dash. Had to cut out a bit of the dash and some of the metal support structure behind it. I also fabed up a 4 guage face plate out of 7mm marine ply, coated it in plasti dip and secured to tot he dash using 4 screws.

Power for the gauges was spliced into the cig lighter circuit. The rest of wires from the sensors came through the passengers side firewall hole. Also got a pillar pod and mounted a boost guage. Too bad I'm only getting 13 - 14 psi but that's another story......

 

[bods]

Looks pretty good.. Are you going to fit an egt gauge to keep an eye on things when you fit the bigger tyres?

 

[dilmah]

Guages front left to right
Green:EGT
Red: Pre I/C temp
Red: Post I/C temp
Blue: W2A water temp