Tom M'Guinn

Anyone have intercooler upgrade experiences to share -- either end-tank mods, fmic or other replacements? I'm mulling over options and would appreciate hearing from those who've upgraded. Thanks.

DDP

Are you keeping A/C?

Lorax

It seems like there is plenty of room for an FMIC if you cut part of the bumper bar, but you were asking for experience and I haven't done it yet. Hopefully in the next couple of months.

Tom M'Guinn

Yes. Should have mentioned that.

aribop

There's no need to cut the bumper bar. I cut the intercooler mount/crossbrace and welded in a 3/4" piece of square tubing and mounted the intercooler and my oil cooler to it.

Lorax

Albert, what are the dimensions on that IC? I'm going to copy you.

V2Rocket

jesus aribop the size of that thing..

why such massive ducting? lol

aribop

Ryan,
I believe it was around 25" across (just barely fit between the frame rails) and 4" thick and like 18" tall? Man, I can't remember exactly. You can look at the pictures and take some measurements on your car. The top came just below the top of the bumper bar and it went down as far as the bumper cover. I had to notch the bottom inside of the bumper cover for clearance.

porschefig

Wow, that should be a complete kit w/ the ducting, oil lines, and everything! Well done!!

My only question. Why make the inlet/outlet on the intercooler bigger than the intercooler pipes? Wouldn't that be a bigger pressure drop as it enters the intercooler and more flow restriction as reenters the smaller i/c pipes?
(I don't know, but I'd like to learn)

EDIT: Were you using a "vented" nose panel?

Lorax

It doesn't really make a difference. The pressure dop of a massive IC is much bigger than the pressure drop of going from 2.5" to 3", think about it.

Also it means if you want to go to 3" IC pipes later you are set

aribop

Yes, vented header panel.

Tom M'Guinn

Looks good Aribop -- your craftsmanship is always first rate. Did that start life as SFR parts, or did you build it all from scratch?

porschefig

You're right, I only thought of the cross sectional area getting bigger going into the hoses, and forgot about it getting even bigger in the side tanks of the intercooler. I didn't think about the whole picture.

My question should be: Why such a thick intercooler?

EDIT: I see the SFR I/C is 23x8x3.5 and should flow 750 cfm at 1.5 psi pressure drop. That's both thicker than I expected and less pressure drop than I expected, but this I/C is WAY bigger.

aribop

All from scratch, Tom. Well, the intercooler pipes are SFR.

evil 944t

Tom,

Whatever IC you buy, make sure its a real Spearco core (or Bell). The core makes all the difference. Bell is in TX and they can make a custom IC to your dimensions/specs. Make sure its rated for your HP. Its more money than a Ebay IC but should you do anything else, your wasting your time. You have a nice car and a lot of good parts, don't cut corners on this.