intercooler spray kit!! top mod

[Doug_RS2]

KramRS2 - interesting read.

After reading that I would be inclined to use one jet on the rear of the IC aimed over the top of it - i 'll use another one on the front.

Where did you mount your nozzles?

I'm using the Autospeed Controller so uses the difference in IC and Ambient temperature and the load on the engine as trigger points.

[KramRS2]

Hi Doug,
I use a simple button as an activation device. I put the nozzles symmetrically at the top of the IC. Now I’m thinking in putting them closer to the left (viewing from front), where the boosted air comes.
I don’t think that put a nozzle in the back is a good thing cause the air flow will make all spray turn back and go to the wrong direction. At least putting them at front will make all drops makes its way to the IC.

The neuspeed controller is very interesting, but still thus it wastes a lot of water as I understood.

Did you use this device on a track day? How much water it spends?

[Doug_RS2]

I've not used mine yet - it's not even fitted. I will try and fit it this weekend - even if it's just used on the RR it sounds like it will be worthwhile.

[AudiS2Au]

I added an intercooler water spray this week. It produces a fine mist onto/in front of the intercooler, and would have to make some difference with the heat here!.

My setup uses some of the components AutoSpeed suggested in this article.

Intercooler Water Spray

Namely the VDO pump from a Holden, and the Spraying Systems brass conject nozzle and filter/check valve. I will try and take some pics and post tomorrow.

Water is sourced from the front windscreen washer reservoir, located under the front left side guard (remove the wheel liner to get at it).

For vehicles fitted with the headlight washers (Not sure if this was an option on the S2's?), this reservoir has holes for two pumps - one for the windscreen, one for the headlights. If the latter is not fitted, a sealing plug should be in its place.

ETKA pic of Windscreen Washer system

I am not sure how strong the headlight pump is, but I decided to replace it with the Holden pump (since Autospeed suggested it was reasonably powerful), which happens to slot straight in (with its little gasket/filter). I had also considered fixing another reservoir and pump in the rear at the right hand sidne in the luggage area, where that plastic bucket is. I'm happy to have avoided running water lines from rear to front of the car though!

5m ID tube then goes along the same route the headlight washer tube does to a length of 12mm ID tube where it connects. On either end of the 12mm tube are the spray nozzles, which are positioned at either end of the intercooler.

A relay and a switch inside the cabin activates the pump. The Holden pump apparently pumps about 200ml/min, and I understand the reservoir holds about 4.4 litres, so about 20 minutes run time?

In terms of automatic control of the system, I am waiting on AutoSpeed's intelligent water spray controller.

Intelligent Water Spray Controller

It comes with sensors to monitor outside air temp, intercooler core temp and monitors injector duty cycle (load) to decide when to turn on and off the spray. The controller triggers a relay for on/off, and I think I will install an override switch when I wire it in.

Interested in comments, and I'll update when I have the controller installed.

I also notice a similar setup has been achieved with a late model S4

Water Spray on Audi S4 - audizone.com

[Doug_RS2]

Look forward to seeing some pics.

I got a water bottle out an Audi 100 - it has the 2 pumps and level sensor. I was hoping to fit it under the bonnett but it 4.5litres and i think I would have trouble, even with a heat gun to get it fitted. I never though of fitting in in the raer - I might try and see if it fits in that cubby hole.

AudiS2Au - Are you using one or two nozzles? I might use a lot of water with 2 nozzles but it isn't on all the time - can only try it and see.

[Greg_S]

Doug,

How about behind the drivers side front wing down near the oil cooler duct?

[Doug_RS2]

Didn't think there was enough room there. I'll have another look tomorrow.

[Lee]

Calling Minhea!

Minhea, could you use the ECU do drive the intercooler spray? There are six channels and only 5 used for injectors. I thought there was a spare driver. Could you link it win with the main map to spray water only when required. The Autospeed one is adaptive but you might be able to make the cooling reactive by writing the code into the ECU. Would be great if it's possible.

Doug, I can't wait to see all this stuff on your car. You are making really good progress on your mods. Are you going to have the spray sorted before next weekend?

[Mihnea]

Re: Calling Minhea!

Originally posted by Lee
Minhea, could you use the ECU do drive the intercooler spray? There are six channels and only 5 used for injectors. I thought there was a spare driver. Could you link it win with the main map to spray water only when required. The Autospeed one is adaptive but you might be able to make the cooling reactive by writing the code into the ECU. Would be great if it's possible.

Doug, I can't wait to see all this stuff on your car. You are making really good progress on your mods. Are you going to have the spray sorted before next weekend?

Well, I had already thought of this idea to use 1 spare injector driver channel and 1 spare coil driver channel for 2 and 3 additional injectors but unfortunately, the M2.3.2 system doesn't allow doing so. I have a fair idea of what the program code (assembly language) should look like but there's no way to implement it in the current chip, BTDT and it doesn't work. I think the first systems that allow implementation of additional channels in the ECU are the ones used on 2.9l VR6 engines, but as they are for 6 cylinder engines, it's quite a lot of work to do to adapt the ECU to a 5-banger...

[Doug_RS2]

Re: Calling Minhea!

Originally posted by Lee
Doug, I can't wait to see all this stuff on your car. You are making really good progress on your mods. Are you going to have the spray sorted before next weekend?

Don't think I will have this on the car - if I don't, I will bring the nozzles attached to a stand so we can all use it on the RR

[timucin]

i will build my own spray kit in 10 days but i will be spraying nos.will send the pics..

[Lee]

I looked into spraying liquefied gases and using their rapid expansion to cool an intercooler. I considered Nitrous Oxide and Carbon dioxide due their high storage densities at reasonable pressures (about 60 bar or 900psi which is fire extinguisher territory). But, water/alcohol mix has amazing thermodynamic properties though and it's latent heat of evapouration is very impressive. Being so cheap it is very hard to beat. It doesn't freeze which is useful for us in the UK Winters (as are liquefied gases). I've got a CO2 fire extinguisher and have located some suitable solenoids for around 35UKPounds ready for the kit but these parts are probably going to be put to better use in a homemade Nitrous kit. I'll stick with water/alcohol for my imminent intercooler spray kit. It is a top mod whatever you choose to do. Please post pictures of your install as I would really like to see it. There are going to be quite a few, very different, installs so it would be usefule to others planning a kit to see the various solutions to this task.

[timucin]

i finished mine, didnt try but i am not satisfied, will do better nozzles for better cooling including sides;

here is the pic

[timucin]

this yellow pipe has 16 holes to sprey nos. what didnt work as planned is the flow; its not becoming spray it goes straigt. and i forgot the side tubes of the cooler
now planning smthng iwhich i believe will be more efficient

[timucin]

i will make a better one next week, redpoints are new nozzle points. the ones i did was circle but they have to be more like 'I' .



will post the better sprey kit next week