Frederic's radiator cooled intercooler.

[Roy]

>  Hello all
>
> I have been reading this thread and would say that
> an air to water intercooler system is the way to go.
> The way to design the system is to aim for 
> overcooling of the coolant by using an intercooler >
designed for marine use and a pump to assist the >
flow through a radiator, you do not need high flow >
rates.  When you are on boost it will take time to >
raise the volume of water from ambient temperature >
towards boost temp, and then as soon as you are off >
boost the system is cooled back down again.  It all >
depends upon  the vehicle and how it's > being used.
>
> Where I am currently working, on engine testing we >
use this type of intercooler because it is easier to >
control boost temperatures more accuratly for >
calibration , but with closed system we can achieve a
> 85% reduction in boost temp.  What you need to check
> is the pressure differential across the intercooler,
> we use " BOWMAN INTERCOOLERS " made by Bowman >
engineering here in the UK in Birmingham.
>
>    hope this helps Roy 
>                Spectric's Ltd


--- Daniel Ciobota <dciobota at hiwaay.net> wrote:
> I missed the beginning of this thread, but
> Frederic's intercooler project caught
> my eye.  I did a similar project last year along the
> same lines, but the results
> were a bit disappointing.  here's what I did:
> 
> My engine at the time was a supercharged 5.0l
> mustang motor, putting out 390rwhp
> with 7psi boost at the throttle.  I was running a
> buick boost retard at the
> time, and I wanted to run max timing on pump gas. 
> The only way to do that was
> to cool down the incoming charge (205deg) down to
> about 110-120.  There are
> water/air intercoolers for those motors, but they
> cost $1000+.  I wanted
> something cheap.
> 
> The system I put together was made of the following:
> One transmission oil cooler (24x6x1"), cut in half
> lengthwise, making it a
> 24x3x1"
> One transmission oil cooler, same as above but not
> cut.
> One RV water supply pump (40gph, 9psi static
> pressure, I think).  It was
> something like $70 at the rv supply place.
> One windshield washer tank, modified to accept 3/8"
> hose.
> 3/8 hose.
> 
> The way I set it up was this.  I inserted the cut
> cooler into the intake plenum
> (a cobra intake) by removing the 3" plug off one
> side of the plenum, and welding
> a plug on one end of the cooler, with lines running
> through.  I aligned the
> cooler so the air had to go through the cooler to
> get to the runners.  The pump
> would pump water from the other cooler (the
> exhanger), through the plenum cooler
> and back into the water tank.  On race day, the pump
> would be reversed  and the
> water tank be filled with ice water for max cooling.
> 
> I took the setup to a flow bench and did
> before/after flows with the plenum
> cooler.  Then, I ran a temp test with the cooler not
> running and the cooler
> running ice water (35deg).  With an incoming air at
> 120deg, the outgoing air was
> a mere 5 deg cooler!  The water temp hardly changed.
>  This was on an upper
> intake flowing 273cfm on the flow bench.
> 
> Soo, my take on the trans cooler idea was that it
> was not nearly enough, at
> least not for that setup.  Albeit Frederic's setup
> has a cooler at least 4 times
> the volume probably, I think it's the exposed
> surface area that counts.  I've
> looked at Vortech water/air intercooler, and it has
> a much larger surface area
> that even the largest trans coolers.  Fred, are you
> going to do some numbers
> testing on that beast?  I'd like to know what kind
> of temp drop you're getting
> at what flow...  maybe I gave up too soon, but my
> results were pretty
> discouraging.
> 
> Btw, I still have the water pump, the tank and the
> coolers if someone wants to
> play with this some more...
> 
> Daniel
> 
> 
> 
> 
> 

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