Large IC install/pluming

[Rusty]

This all looks rather interesting. Damn this site for making me spend all my money!

Bo, once you get a price of crossmembers and have checked the fit, please let us know

Nice work all, the site appears to be awash with analysis of the technical aspects of "S2 playing about with". Nice!

[Dpicariello]

Resistance is increased by the length of the path through the IC, double pass IC has more resistance than single pass but also a single pass has more cross sectional area so less resistance for this reason too. In terms of a pipe: Double pass = twice as long, half as wide. Single pass = half as long, twice as wide. ( for the same overall core size and discounting the extra plumbing for the single pass) I'm not really up on fluidics so I don't know if thats 2x2 or 2squared..

I was looking at these double pass units too, thinking it would be so much easier but I think the single has to be way more efficient.

Good point,

I think that the cross sectional is squared and multiplied by the drag coefficient for drag

I tell you what, (putting flame suit on) I'll model both methods in a fluid package I have at work . May be a bit extreme (and quite geeky) but could give a better idea of losses because this really is a simple install.

[newsh]

Resistance is increased by the length of the path through the IC, double pass IC has more resistance than single pass but also a single pass has more cross sectional area so less resistance for this reason too. In terms of a pipe: Double pass = twice as long, half as wide. Single pass = half as long, twice as wide. ( for the same overall core size and discounting the extra plumbing for the single pass) I'm not really up on fluidics so I don't know if thats 2x2 or 2squared..

I was looking at these double pass units too, thinking it would be so much easier but I think the single has to be way more efficient.

[Dpicariello]

Right, just measured the vertical distance between inlet and outlet pipes (inlet on the intercooler and outlet on the cross member pipe) on the standard ABY intercooler. It measures 160mm. The intercooler with inlet and outlet on the same side has a core height of 12" and therefore a radius of about 150mm.
So the radius is 10mm tighter on this intercooler than the standard one in effect.

So it's not as bad as I first thought with this type.

Intercoolers on ebay in this style only come in 790mm lenght versions which is bloody big but he does do a medium version (I have emailed him asking for availability). I reckon this would fit perfecty and require just two 90deg peices to connect the pipes.

If Bo can get the cross member sorted (cheers for that Bo) then thai could be an easy option. However, I'm interested to see how the big one will be fitted as that does look fantatsic.

Keep up the good work Bo!

[s2_bo]

Bo, if this works you can do kits of Pipes and Crossmembers for others too. Thats my problem too. I wanted one of those IC but with the rad in place and the stock IM.

Yeah no reason why not.

Im taking all the Stainless to the Metal shop behind work on Monday. He can then give me a price and some sort of a time scale, hopefully it won't take to long.

@ Dpicariello. Yes mate, no problem. once its finished ill let you know the total price inc Steel and welding.

@ newsh. Thanks for that, will give it a try. IIRC the hoses also stretch a fair bit further if you get them hot with boiling water first.

Cheers guys.
Bo

[topsparky]

There's not enough room behind the urS4 bumper for even a small intercooler let alone one that size! I'm planning on using an S6 bumper to try and gain a little more space but even then I'll have to use a considerably smaller intercooler than Bo's!

it's about the same size as smog fitted to his
check audifans matey

[Billman]

Bo, if this works you can do kits of Pipes and Crossmembers for others too. Thats my problem too. I wanted one of those IC but with the rad in place and the stock IM.

[s2dude]

I'm no pro tuner but do spend my days working on flow modelling within pipes!

Flow wise, the down side is that you have a sudden change in direction within the cooler. The air velocity (I have no idea what it is within the boost pipes) will dictate how harmful this is to flow.
However, you get a dual pass unlike a straight through left to right cooler so it should be slightly more efficient in terms of heat exchange.

I think I am going to go with this one though purely because if the ease of plumbing it in.

Agree with this.
Im no expert but I know this is not a good design in terms of pressure loss. Cant find the link ATM but there was a good article on IC designs and this type was not favoured at all due to the air having to do a complete U turn on entry/exit to the IC..

[newsh]

Bo, you should be able to stretch the 54mm Samco over the 60mm tube, I'm using a piece of straight Samco hose from CM to Inlet tube where the michelin man tube used to go and it pretty easily stretches up a size.

[Dpicariello]

Waiting on a tuner to respond! Deffo be easier but whats the flow going to be like?

I'm no pro tuner but do spend my days working on flow modelling within pipes!

Flow wise, the down side is that you have a sudden change in direction within the cooler. The air velocity (I have no idea what it is within the boost pipes) will dictate how harmful this is to flow.
However, you get a dual pass unlike a straight through left to right cooler so it should be slightly more efficient in terms of heat exchange.

I think I am going to go with this one though purely because if the ease of plumbing it in.

[Dpicariello]

Whats the verdict on this IC? - The pipework would be so much easier.

That's the one I am thinking of getting Bo but it's even wider than the one you have gone for! That chap does a slightly smaller one with inlet and outlet on the same side but the only one he has is sightly damaged.
I measured up this morning for the large one with inlet and outlet on both sides and reckon it will fit. I like you really don't want to lose the aux rad and also don't want to mess around with the oil cooler duct.

When do you reckon you will be able to get the cross member by and is there any chance of you getting me one for the same time?? Sorry to be a pain but I'm itching to get this installed.
I was meant to be going out driving tomorrow morning with some mates but the fact that my intercooler is lying helplessly on the garage floor means I am having to play passenger (oh well I get to go out in a 600bhp RUF GT2 )

[Jamo]

Whats the verdict on this IC? - The pipework would be so much easier.

Waiting on a tuner to respond! Deffo be easier but whats the flow going to be like?

[s2_bo]

Whats the verdict on this IC? - The pipework would be so much easier.

[Jamo]

They are so cheap it's worth it!

Just fitting is a problem. I've got plans for a charge cooler and have finally identified the perfect one. :mischeif:

All I need now is the cash Booooooooooooooooooooo!

[merlin's S4]

nice one bo i'm thinking of getting the same
one for my urs4 only it's £15 cheaper
coz i only live 18 miles away
p.s bo
are the bottles underneath for water injection

There's not enough room behind the urS4 bumper for even a small intercooler let alone one that size! I'm planning on using an S6 bumper to try and gain a little more space but even then I'll have to use a considerably smaller intercooler than Bo's!