Intercooler is in...
 

I did in fact meet my goal of having the intercooler installed 2 weeks after it arrived... Unfortunately I didn't count on the rear high speed seal of my Procharger going from a small drip to a huge leak at the same time. Should have the Procharger back on Monday, it left a P1SCH and is coming back a bigger and badder D1SC. Everything on the car is ready and waiting... can't wait find out the power gains, I'm expecting my current 140-150F WOT air temps to drop down to hopefully 10-15F over ambient at max. That should make a very, very noticeable difference in power.

Anyways, here's the pics. The intercooler was designed by me and built by Bell Intercoolers. The core is 27" x 12" x 3" and flows 1400cfm with 1 psi pressure drop.

It was a fun project... relocate the battery, completely hack up and rebuild the factory radiator support, put in a new larger AC condenser and remake the hoses and move the receiver/dryer, install a power steering cooler, etc. I managed to keep the factory hood latch intact and didn't have to cut the bumper, grille, valance, or anything else.

Anyways, pics:

http://home.comcast.net/~swedish_che...f/icsmall1.jpg
http://home.comcast.net/~swedish_che...f/icsmall2.jpg
http://home.comcast.net/~swedish_che...f/icsmall3.jpg
http://home.comcast.net/~swedish_che...f/icsmall4.jpg
http://home.comcast.net/~swedish_che...f/icsmall5.jpg

More details and pictures on the intercooler link on the webpage in my signature.

Can't wait for the fedex guy to bring my Procharger to me on Monday. I'll also post more pictures of everything installed then.

looks great Troy! Especially like the beads on the ends of the piping, look great. :P

Jody

Cool..I know a guy that would like to borrow it the first week of June......

LOL! Only if I get one of those spiffy styrofoam fuel coolers in the trunk when I get it back. :rofl:

you two are hilarious. :rolleyes: :D

Jody

Nice job Troy !! Keep us posted on the differences between the old and the new. We need another good fly-by video...

Question for you, Jody or Charley - do you guys know of or do any of you use an air temp gauge to monitor inlet temps ?

Looks good!!

it's monitored and adjust automatically in the efi system. I do not have a separate air temp gauge, but can monitor or datalog it through the laptop.

Jody

Not to hi-jack but do we know anyone that has a bead rolling machine? I'd love to have it done instead of just welding a bead on the pipe.

Thanks for the info Jody. A laptop is a wonderful thing...

I borrowed one from Jody... hence his ribbing about the beads in his first reply. :rofl:

He has one of these:

http://www.beadform.com/beadform1.html

Works great! :thumbsup:

Thanks. He and I talked about it the other day.

Got the D1SC back today and put everything back together... the intercooler has exceeded all my expectations.

68F outside air temp tonight, minimal water injection (I cut back from two to one 5GPH nozzle and also dialed the controller down) and the IAT's never went over 84F even at maximum boost.

I couldn't believe the datalog the first time-- the IAT was 82F during steady cruise at 2500rpm where I started the log and at 15psi/6600 rpm the IAT was only 84F. I tried it multiple times back to back and couldn't get it to heatsoak, all the datalogs were the same-- the IAT stayed within 80-84F no matter what my right foot was doing.

Injector duty cycle at peak torque went up about 6% over non-intercooled; the 6% duty cycle increase is 36pph of fuel with my 75# injectors. The extra 36pph of fuel consumption at a .60BSFC computes to about an extra 60hp worth of fuel and the butt-dyno agreed. I haven't tried adding any more timing yet but should be able to given the reduced intake temps.

The D1SC is significantly louder as far as impeller/air noise than the P1SCH. The gear noise is the same but the D1 impeller has a much more pronounced high pitch air "whistle" to it. I'm not thrilled with the extra noise but oh well. I re-used the same 4.25" pulley I was running with the P1SCH with the new larger D1SC and boost in the intake is the same-- the D1SC upgrade simply offset the pressure drop across the intercooler.

Here's some mediocre pics from my mediocre digital camera. LOL.

http://home.comcast.net/~swedish_che...icfinished.jpg
http://home.comcast.net/~swedish_che...cfinished2.jpg

Next up-- take the 4" stainless mandrel bends I have and build a new intake for the supercharger to get rid of the neoprene/fiberglass spiral wound flex ducting.

man that car is kool we need some more pics of the whole car. what kinda numbers were you putting down before?

Looks great!!! How much rwhp do you expect to make, if you don't mind me asking.

I'm thinking with the intercooler and larger blower he has to be as good as my friends car, and that was 700 rwhp.

Good job Troy.

Jody

looks good, now post vids. . . do I need to bring ye olde handy-cam to work?

now you just need a smaller pulley and more timing. . . and more tire.

the car is nuts.:willy: