Building A Water To Air Intercooler

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panel
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Re: Building A Water To Air Intercooler

Post by panel » Sat Apr 04, 2015 2:49 am

Also don't forget to insulate it...........viewtopic.php?f=3&t=139988

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risk
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Re: Building A Water To Air Intercooler

Post by risk » Fri Apr 10, 2015 11:24 am

panel wrote:Also don't forget to insulate it...........viewtopic.php?f=3&t=139988
What about some kind of coating? Like a ceramic or heat insulating type?

http://www.yellowbullet.com/forum/showt ... p?t=430122

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risk
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Re: Building A Water To Air Intercooler

Post by risk » Mon Apr 13, 2015 6:52 am

Intercooler is done! Now I just need to pressure test it again and make sure there are no leaks.
20150413_061104.jpg
Ended up cutting the end piece in two, then welding each one to it's respective end tank.
20150413_061112.jpg
My welds aren't the prettiest but they get the job done.
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risk
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Re: Building A Water To Air Intercooler

Post by risk » Tue Apr 14, 2015 2:05 pm

Well.. Almost done. I need to add some bungs for temp sensors so I can measure delta T.
20150413_174006_resized.jpg
I think I'm just gonna paint it black, then engine turn the front panel to match my firewall.
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panel
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Re: Building A Water To Air Intercooler

Post by panel » Sun Apr 19, 2015 12:59 am

Nice intake manifold!

Steve Arndt
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Re: Building A Water To Air Intercooler

Post by Steve Arndt » Sun Apr 19, 2015 9:09 am

Post a pic of your throttle cable and linkage (cable through shroud still?).

Is that a Ford throttle body?

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risk
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Re: Building A Water To Air Intercooler

Post by risk » Tue Apr 28, 2015 4:14 pm

Steve Arndt wrote:Post a pic of your throttle cable and linkage (cable through shroud still?).

Is that a Ford throttle body?
I will post up a pic once it is all back together. Unfortunately, I didn't have room to run the cable through the shroud like I wanted to. The intake is just too wide right there.

Yes, Ford throttle body off a V8.. around 65mm throttle plate.

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risk
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Re: Building A Water To Air Intercooler

Post by risk » Tue Apr 28, 2015 4:16 pm

Still working on getting the engine put back together, but I did get the engine turned finish put on the intercooler.

I plan on painting the end tanks and piping black, then clearing over the engine turned portion.
20150424_174131.jpg
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andy198712
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Re: Building A Water To Air Intercooler

Post by andy198712 » Tue Apr 28, 2015 4:22 pm

Nice!

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yvre
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Re: Building A Water To Air Intercooler

Post by yvre » Tue May 05, 2015 2:38 pm

Nice work! Looks like it fits very nice.

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risk
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Re: Building A Water To Air Intercooler

Post by risk » Thu May 21, 2015 8:53 am

Intercooler is installed and working well, no leaks! Took it for a drive and did some logging so I could figure out the efficiency. After it was completely warmed up, I took it out on the freeway and flogged it some.

Temp on the intercooler inlet side spiked to 245*F when on boost.

Temp on the outlet side was rock steady at 115*F, would spike to 125*F when on boost.

Ambient air temp was 80*F

So, correct my math if I'm wrong, but:

245-125 / 245-80 = 73% efficient

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rubenski
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Re: Building A Water To Air Intercooler

Post by rubenski » Thu May 21, 2015 11:35 am

Wow, nice!
Better to be blown than to suck!

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Stripped66
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Re: Building A Water To Air Intercooler

Post by Stripped66 » Thu May 21, 2015 12:32 pm

Great job! Other details of the setup...are you using a heat exchanger? What size water tank?

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risk
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Re: Building A Water To Air Intercooler

Post by risk » Thu May 21, 2015 1:14 pm

Stripped66 wrote:Great job! Other details of the setup...are you using a heat exchanger? What size water tank?
Tank is a small 2 gallon aluminum located in the package tray. Heat exchanger is mounted underneath, next to the transaxle.. it's just a radiator off a ninja motorcycle, with an aftermarket 10" elec fan and homemade shroud. I need to take some pictures of everything and post up. I chose that radiator because it fit in the area, plus it had 3/4" inlet/outlet that matched everything else. Pump is a Bosch part # 0 392 022 002

Everything worked out great, although I don't like the idea of a tank full of hot water in the cab.. I may move it up front under the hood eventually.

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risk
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Re: Building A Water To Air Intercooler

Post by risk » Thu May 21, 2015 1:15 pm

My next project is gutting my gas heater, and putting a heater core inside so I can use this hot water in the winter for heat :D

Something like one of these..

Image

Image

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