My New Custom Intercooler..& Other Items..Lots of Pics
10-03-2005 | 12:45 AM
#1
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From: Houston, TX
My New Custom Intercooler..& Other Items..Lots of Pics
Well I have been working on the design and fabrication of this intercooler for the past 8weeks and finally its done. My aim was:
1) Retain the A\C
2) Have it fit under the stock hood
3) Make it extremely efficient, minimal psi drop and overall well designed
4) Have a core larger than the Kokeln (which is 642cu.in)
5) Cheaper than the Kokeln
6) Easy to remove
7) Has to look good!
The results:
1) A\C retained - Yes!
2) Fits under the stock hood - Yes with some convincing (wink)!
3) Efficient - Yes!!! - Bar and plate core - rhomboid shaped, giving the air slightly more distance to travel and hence cool before entering the TB. The rhomboid core was extremely difficult to cut and mate to the end tanks, as opposed to the typical square \ rectangular IC cores. Pressure drop only 0.45psi at 14psi inlet.
4) Core volume - 685cu.in, so larger volume that the Kokeln
5) Cost was cheaper than the Kokeln
6) I can remove it in about 10minutes
7) Looks incredible - I think!
The intercooler was finished last week and I had a few fitment issues, the main one being that the hood could not close, as it was catching on the left corner of the new IC plus the rear window wiper motor was also rubbing on it.
So no probs...I removed the rear wiper motor + wiper assembly (trickier than it looked) and then used my grinder to do a little bit of massaging on the hood. I am not at all concerned with the removal of the rear window wiper motor, to be honest, and I have seen alot of guys remove this motor when they fit these larger intercoolers. I also removed the Decel. Valve while I was also at it (man that was a pain in the butt to remove!). Here is the hood after the massaging with the grinder:
Decel valve removed:
BTW: If I had made the IC 1\4" of an inch narrower it would have been perfect, no massaging required.
I decided to make a new turbo outlet pipe and use regular silicone couplings and T-Bolt clamps, rather than use the heavier cast factory O-ring pipe. The new outlet pipe I made started life as a flat sheet of aluminum and then I had my friend TG weld it and I put donkey dicks at the ends to keep the silicone couplings from blowing off under high boost and then I shaped it as well to give it the factory angle at the top - took 1hour to make.
My new aluminum outlet pipe next to the factory unit:
Fitted on the car and polished!
The factory intercooler next to the new one, notice the big differences are in overall thickness and much greater surface area:
I polished the new IC before installing it:
Car runs fantastic and I pushed the car extremely hard tonight, came home and the top of the intercooler was moderately warm, the stock IC would be scalding \ "fry and egg" hot. No leaks and no issues.
That's it for now!
Yasin
1) Retain the A\C
2) Have it fit under the stock hood
3) Make it extremely efficient, minimal psi drop and overall well designed
4) Have a core larger than the Kokeln (which is 642cu.in)
5) Cheaper than the Kokeln
6) Easy to remove
7) Has to look good!
The results:
1) A\C retained - Yes!
2) Fits under the stock hood - Yes with some convincing (wink)!
3) Efficient - Yes!!! - Bar and plate core - rhomboid shaped, giving the air slightly more distance to travel and hence cool before entering the TB. The rhomboid core was extremely difficult to cut and mate to the end tanks, as opposed to the typical square \ rectangular IC cores. Pressure drop only 0.45psi at 14psi inlet.
4) Core volume - 685cu.in, so larger volume that the Kokeln
5) Cost was cheaper than the Kokeln
6) I can remove it in about 10minutes
7) Looks incredible - I think!
The intercooler was finished last week and I had a few fitment issues, the main one being that the hood could not close, as it was catching on the left corner of the new IC plus the rear window wiper motor was also rubbing on it.
So no probs...I removed the rear wiper motor + wiper assembly (trickier than it looked) and then used my grinder to do a little bit of massaging on the hood. I am not at all concerned with the removal of the rear window wiper motor, to be honest, and I have seen alot of guys remove this motor when they fit these larger intercoolers. I also removed the Decel. Valve while I was also at it (man that was a pain in the butt to remove!). Here is the hood after the massaging with the grinder:
Decel valve removed:
BTW: If I had made the IC 1\4" of an inch narrower it would have been perfect, no massaging required.
I decided to make a new turbo outlet pipe and use regular silicone couplings and T-Bolt clamps, rather than use the heavier cast factory O-ring pipe. The new outlet pipe I made started life as a flat sheet of aluminum and then I had my friend TG weld it and I put donkey dicks at the ends to keep the silicone couplings from blowing off under high boost and then I shaped it as well to give it the factory angle at the top - took 1hour to make.
My new aluminum outlet pipe next to the factory unit:
Fitted on the car and polished!
The factory intercooler next to the new one, notice the big differences are in overall thickness and much greater surface area:
I polished the new IC before installing it:
Car runs fantastic and I pushed the car extremely hard tonight, came home and the top of the intercooler was moderately warm, the stock IC would be scalding \ "fry and egg" hot. No leaks and no issues.
That's it for now!
Yasin
Last edited by slownrusty; 10-03-2005 at 03:26 AM.
10-03-2005 | 09:12 AM
#7
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From: Concord, NC
As always for some reason, I can never view slownrusty's pics. They never show up for me for some reason. Are you hosting those pics on a **** server or something that my firewall here at work is blocking??? 
Brian
Brian
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10-03-2005 | 10:53 AM
#10
Thread Starter
Rennlist Member
Joined: Apr 2005
Posts: 2,879
Likes: 337
From: Houston, TX
Thanks for all the compliments guys!! Much appreciated, this was quite a bit of work to see it through to completion, but the end results speak for itself.
Brian - Yup...you figured me out buddy! How do you think I can afford all this...internet **** all the way...LOL...here is the URL to my pics off my website:
http://www.picturetrail.com/gallery/...561&uid=504386
JWL - sadly no I did not do the TIG welding...I wish I could, that is the next thing on my "To Do Learn" list! If it was me you would see splatter and burn through all over the place..!
Regards - Yasin
Brian - Yup...you figured me out buddy! How do you think I can afford all this...internet **** all the way...LOL...here is the URL to my pics off my website:
http://www.picturetrail.com/gallery/...561&uid=504386
JWL - sadly no I did not do the TIG welding...I wish I could, that is the next thing on my "To Do Learn" list! If it was me you would see splatter and burn through all over the place..!
Regards - Yasin
10-03-2005 | 10:57 AM
#11
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Joined: Apr 2005
Posts: 2,879
Likes: 337
From: Houston, TX
Anyone want a beautiful perfect B&B (polished)...its up for grabs! Reasonably cheap too, pls contact me at slownrusty@yahoo.com
Regards - Yasin
Regards - Yasin
10-03-2005 | 11:03 AM
#12
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Joined: May 2005
Posts: 2,261
Likes: 1
From: Cooterville, Carolina
Originally Posted by slownrusty
Anyone want a beautiful perfect B&B (polished)...its up for grabs! Reasonably cheap too, pls contact me at slownrusty@yahoo.com
Regards - Yasin
Regards - Yasin
10-03-2005 | 02:32 PM
#14
Drifting
Joined: May 2005
Posts: 2,261
Likes: 1
From: Cooterville, Carolina
Originally Posted by jwl
Oh c'mon sand_man, you know this intercooler won't look good on your white car. Don't ya think it would look much better on a meteor metallic? 
Yasin...cash has been sent! Thanks Bro!
