[JaxChris]

Refrigerant coil on top of existing intercooler and electric AC pump to drive it. Put a lip around the top of the intercooler to prevent water from dripping on the track. Place a reducer on the charge pipe by the rear axle to increase air pressure. Have the pipe enlarge in the engine bay to increase air vacuum across the bottom of the car. Thermal wrap or ceramic coat the charge pipe to lower heat soak from the transmission and engine.

Probably all bad ideas, but it works in PC's and their components run as hot as a car does. Just a difference in size of materials.

[cellsafemode]

Originally Posted by JaxChris

Refrigerant coil on top of existing intercooler and electric AC pump to drive it. Put a lip around the top of the intercooler to prevent water from dripping on the track. Place a reducer on the charge pipe by the rear axle to increase air pressure. Have the pipe enlarge in the engine bay to increase air vacuum across the bottom of the car. Thermal wrap or ceramic coat the charge pipe to lower heat soak from the transmission and engine.

Probably all bad ideas, but it works in PC's and their components run as hot as a car does. Just a difference in size of materials.

Fail. Lack of heatpipes, peltiers, and/or the suggestion to to enclose the charge tube in mineral oil that is cycled around that refrigerant coil.

Or just arctic silver epoxy a ton of copper heatsinks to the charge tube and add a number of fans to them. With some ducting to a push-pull setup with direct cold-air access.

[Goertz]

Yeah I've built quite a few pc's also

This is my current rig I built a couple years ago.

AMD Am3+ 8350 watercooled processor (8core 4ghz per core, haven't oc'ed yet)
AMD R9 290x Saphire Reference (will watercool later)
16gb ddr 3 1600mhz (haven't oc'ed yet)
64gb ocz ssd sata 6 (got this years ago when ssd were crazy expensive still, OS only)
1tb wd black sata 6 (years ago also, 1 tb just came out when I got this)
Custom waterloop I designed, huge reservoir as you can see, 120mm x 2 x 80mm radiator with 140mm fans mounted up front to push (largest will fit on case) 120mm pullers on back of radiator (tons of airflow, will suck the door closed!)
850watt powersupply (will need more power later)

I use to hardcore game back in Quake 3 Rocket Arena and Counter Strike 1.6 days

Now I dabble on Diablo 3 and just waiting for Diablo 4. It's good having the power I need to play anything that might catch my attention but mainly I just use this as my work rig now for solidworks designing and cfd. After having a wife and kid and no longer single soldier in the barracks I find my lack of time and enjoyment to dedicate to things like games has diminished.

Now I won't lie I will probably disappear for a few months when Diablo 4 comes out hahah

[MIAMI2SSRS]

Beautiful setup, sir!!! It has been quite some time since I had the time to get into something like that.

Now I only "play" with Cisco routers/switches, FW, load balancers, cloud setups, etc.

It was very, very fun though......

[Goertz]

Pulled the intercooler off yesterday and chopped off the cores to rebuild them. Car gets put up on lift tomorrow and all exhaust components come off for fixturing.

I did have a minor setback though, guy I was working with cutting a salary didn't have enough work anymore to keep me a paycheck so I had to move all my equipment back to my shop and go out and hit it for a day job. Good news is I got one with great hours and start next Tuesday.

I choose to keep a day job so I can take my time with my product and make sure it is absolutely perfect and to the best of its ability before I officially release it.

Timeline at the moment:
next week get all fixturing for exhaust components built (this includes the factory headers so I can make a better shorty header).

The following week I finish all new charge pipes under the hood with the new intercooler mounted. Get all charge pipes fixtured as well.

Around the middle of Sep I am testing out my fixtures to 100% ensure they will make a perfect product everytime. I am building new headers as well as my new y pipe and pipe back to the turbo. I am going to experiment with smaller pipes (2.25 header outlet and y pipe to 2.5 back to turbo) This should equate to approx 20% better velocity to turbo and hopefully that means 20% better spoolup. After all new pipes are built everything is being ceramic coated (headers, y pipe, long pipe, turbine housing, etc) and it is finally going back on the car. We're aiming for full boost a near 1000rpm sooner even still. Hopefully we can shift that that 4400rpm peak down to 3400rpm zone.

The downpipe is also going to be rebuilt to be 4" at turbo but y to dual 3" going to BOTH factory exhaust holes. I will likely split those up one final time for 4x tips with a near stock appearance. Combine that with a ceramic coated turbine housing black and powder coated black compressor and everything should kind of hide away for a more sleeper look

As always I'll keep everyone posted as progress is made


**Final testing and dyno will be done with factory intake manifold and factory header**
I will then test with my header swap to see what gains are made

As towards the future to look I will offer 2/3 intercooler options

low boost no intercooler (4-7psi)
moderate boost air to air intercooler for up to 1000whp (up to 20psi)
high boost air to water intercooler for up to 1500whp (haven't decided if this will be a all new intake manifold with intercooler built in, or one in the engine bay) 20++++

[JaxChris]

Originally Posted by Goertz

I use to hardcore game back in Quake 3 Rocket Arena and Counter Strike 1.6 days

Now I dabble on Diablo 3 and just waiting for Diablo 4. It's good having the power I need to play anything that might catch my attention but mainly I just use this as my work rig now for solidworks designing and cfd. After having a wife and kid and no longer single soldier in the barracks I find my lack of time and enjoyment to dedicate to things like games has diminished.

Now I won't lie I will probably disappear for a few months when Diablo 4 comes out hahah

I'll apologize now that I caused this thread jack. But now I'm reminiscing. I miss CS 1.2 (before Steam) but 1.6 will always be the champ. CS Source sucked so hard. My biggest throw back to the LAN party days was Q2 LMCTF. Those two games had such a strong and long hold on me.

Finally started to spread out when Starcraft came out and then C&C Generals took me away from Broodwars. Zero Hour was the best expansion ever for an RTS.

Ugh... did anyone else buy Quake Wars and only make it 2 hours before uninstalling? Total crap. And then I fell back to FPS with the Battlefield series. Only started those games with 2142 and jumped straight to B3 from there. Actually still have my favorite B3 wallpaper on my laptop right now.

Used to use Hamachi to vLAN with my buddies as we all started moving away and had a good little stretch of monthly LAN nights. I miss those. It's been forever since a good frag night. Used to take the pony cars out after some Lo3 pug's and race to Bennigan's for 1/2 price apps and shots before hitting the car club hang outs at Automotive Engineering.

Damn... we used to kick ass and have so much fun... now our cars 250% of what they did back then, Bennigan's is gone, any vice other than wine and marijuana is frowned on and nobody hangs out face-to-face anymore.

This blows. Reminiscing ruined. Now I'm a sad panda. </woot>

[Goertz]

Everything pulled apart to start turning these prototype pieces into finalized production pieces.

Rebuilding intercooler as fmic

Building a nicer brace system for the turbo, this one works but nicer and neater ftw

Fixturing the exhaust side in what I refer to as a "floating" fixture so that different sized pipes can be used in the fixture. Will be rebuilding the y pipe out of 2.25 (currently 2.5) and the main pipe back will be going down to 2.5 (currently 3). Should net us 20% better velocity or there abouts which should turn out a better spool time

Fixturing the stock headers, looks like I can make some serious improvements with these

New setup will work with factory intake manifold (and will be re dynoed with factory intake manifold)

[Goertz]

if your wondering why the welded bars between the flex pipes

everything fit perfect on the car with where the pipes are flexed to. If I unbolt everything the flex pipes will move ever so slightly and that will create a bad fixture. So I weld bars to keep the orientation of the flex pipes and remove everything to fixture in this position.

After this the new parts will be built in perfect orientation from the fixture and flexpipe will be added to accommodate any slight imperfections, stresses from heat cycles, absorb vibrations, etc.

[Goertz]

I am considering running carbon fiber tube down the tunnel by the exhaust pipe.

Although the exhaust will be fully ceramic coated and header wrapped the carbon fiber tube will allow virtually zero heat transfer even if none of those things were done.
The purpose of ceramic coating and wrapping the exhaust will be to get the best possible spool times available.

Also noticed that the spool valve has a sticking point atm.
There were a couple little bugs with it having been our first to machine so a new one is going to be under way to eliminate all these bugs.

Expect to see a completely different beast on the dyno between the improvements in velocity with a slightly smaller pipe to feed to turbo as well as heat retention. Already had a dyno that we were fairly satisfied with having been a completely new game to us (rear mount) and actually getting some decent down load numbers compared to everyone else's "proper" twin turbo setups....

We are learning and only going to improve from here so lets see what the future has in store.

[JaxChris]

Is there a better option for the intercooler mount other than a block of wood? =)~

[MIAMI2SSRS]

Wow

I can't imagine how long it took you to acquire the knowledge/skills to be able design and build something like this.




Thank you for sharing all of this!!!

[Goertz]

thinking about my alternative set of headers being a 180 degree header design

I think a supercar like smooth pulse exhaust note attached to that jetlike turbo hiss on this rear mount could really be a ton of fun




it would be a tri y design 180 degree header.

With my y pipe out and on the ground and my headers out it wont be nothing for me to assemble it all and build a mockup of a engine simulation and my y pipe has it already mapped out for the crossover beneath the transmission to make it all work...

Just some thoughts

[Notorious]

Well as far as the IAT's i don't know if you made your final decision yet on cooling but there is the old saying nothing cools better than water.

Would love to see a air to water setup with a dual fan heat exchanger.

I know your going for a cheaper kit per say, but i think air to water is the way to go.

[Goertz]

Not my car but a friends car that i built the turbo kit on.
He just got it put back together after getting everything back from the coater ( same coater i will use for my kit)
Thought y'alld enjoy the photo.

Tomorrow i finish the fixture to the y pipe and headers. Finished the long exhaust fixture and turbo brace fixture on Monday.